Case 1 : Increase Productivity

Before

  • This customer planned to expand production due to increased order volumes.
  • A new DC was planned and they expected to increase productivity with real time communications with WMS.
  • Inhouse IT staff less to oversee the project.

After

Our system improved customer’s productivity by 35%

  • Orders per day increased by 300%.
  • Productivity increased by 35% over the old facility paper picking.

Solution

  • AIOI SYSTEMS provided Pick-to-Light for the fastest moving SKUs.
  • WMS could directly oversee all the pick areas and integrate with the major vendors.
  • Real time system-to-system communications were centralized to the new operation’s ability to perform as needed,

Case 2 – Increase Work Efficiency by 136%

Before

  • Operators used hand held terminals to scan the barcodes of each product, one by one. This meant that 40,000 products had to be scanned 40,000 times along with the store codes, so shipping was limited to 40,000 to 50,000 items per day.
  • About 17 to 18 company employees worked a total of 1,300 hours of overtime in six months.
  • Larger items were difficult to handle because operators used one hand to operate their hand held terminals.

After

Our system improved work efficiency by 136%

  • The company was able to cut overtime by half. Further creative improvements could also reduce overtime even more!
  • The operation is so simple that even new employees can do it easily.
  • Operators can use both hands to sort and place shoes, bags, and other big items; they no longer have the stress of needing to manipulate large products with one hand.

Solution

  • A barcode reader scans the products.
  • Operators assort only the number of products displayed on the light modules installed on the racks.

Case 3 – Volume Calculator for error-free Picking

Before

  • Operators had to choose between various sizes of cardboard boxes for shipping.
  • Sukeno wanted to automatically deliver the required numbers of the required types of boxes for each recipient.
  • Picking was performed in order of store numbers, so the company was unable to adjust the number of workers by volume.

After

Volume calculation eliminated the need to add labels and repack boxes after picking

  • Informing operators of the results of volume calculations facilitated the supply of right boxes.
  • Automatically delivering the required number of boxes for each recipient eliminated the need to add labels and repack later due to changes in number of boxes.
  • Under the new system, stores having high volumes are finished first, and then picking is done in order of store numbers. This allowed reducing the number of operators.

Solution

Stem tells operators the sizes and quantities of cardboard boxes for shipping to place on the conveyors.

  • The conveyors automatically allocate the required quantities of boxes for each store.
  • The system uses belt conveyors, so empty boxes and shipping boxes can be delivered simultaneously.
  • For each block, operators pick products according to PTL and insert them into the shipping boxes that stop in front of them.
  • To expedite input, a buzzer sounds on the slowest block.
  • A label for an additional box is issued when a shipping box exceeds the preset weight on the scale installed prior to shipping.

Case 4 – Prevent omissions in block relay picking

Before

  • This company uses conveyors and offers small quantities of a diverse array of products, thereby needing to perform picking efficiently.
  • The company sought to increase picking speeds to match conveyor speeds.
  • The company uses a pick by list system using conveyors, requiring error-proofing from omissions and misreading

After

No more backup on conveyors

  • Narrowing the range of tasks per operator by assigning one operator to each block increased picking speed to that of the conveyors, eliminating conveyor backup.
  • Transitioning to a block relay system eliminated omissions, and error-proofing buzzers drastically reduced errors.

Solution

  • To create this system, we added error-proofing features to our Master of Supply Parts with Block Relay software package.
  • Picking speed increased, while waiting for the next pick, operators can also conduct inspections (with a separate system) using wearable terminals.

Case 5 – Increase Work Efficiency

Before

  • With its offering of small quantities of a diverse array of products, this company was unable to improve work efficiency.
  • The company receives a high volume of products with different packaging (in cases, in pieces, etc.); product management required lot of effort.
  • The company needed new hires to compensate for the lack of experienced operators.

After

Pairing with conveyors enabled control of collapsible containers

  • The automatic diversion of collapsible containers to blocks to be picked, dramatically decreased operators’ confirmation work.
  • The picking is guided by light modules, so even new operators can perform the work with ease.
  • Our system clarified inventory control.
  • Our system made it possible to spread work time evenly, reducing wasted work time.

Solution

  • A pick to light system based on a software package that enables picking by installing a Pick to Light system on shelves that hold parts.
  • The software is easy for users to maintain.
  • The system also makes it easy for users to configure the light modules.

Case 6 – Save on Labour

Before

  • Shinnippon Calendar wanted to create a labour-saving system to counter the growing difficulty of securing enough operators.
  • The company was already using a simple put to light system for assorting, but wanted to improve productivity as well as assorting accuracy.
  • The company wanted to reduce walking distances to reduce the burden on operators.

After

  • Pairing the Pick to Light System with piece sorters allows piece sorters to assort flyers as well as the products.
  • This dramatically improved assorting accuracy over the conventional manual labour.
  • Now anyone can perform assorting with only basic training.

Solution

Pairing Pick to Light and Put to Light with piece sorters

  • We introduced piece sorters for small items. We incorporated flyer picking into a Pick to Light System, and paired it with the piece sorters.
  • We built a system that enables assorting by up to 186 users per batch by installing stoppers on the chutes, splitting chute ends in two, and packaging assorted chutes to create empty chutes.
  • We also introduced a multi-put to light system that allows multiple people to assort large and irregular items.