Case 1 – Increased Throughput & Capacity

Before

  • The company had sorter that was very old.
  • The old sortation system ran 19 chutes and able to pack 54 cartons at one time.
  • The equipment was outdated, slow and required high maintenance. This reduced throughput capacity.
  • 134 pairs packed per man hour.

After

  • AIOI installed light system running 17 chutes and pack 272 cartons at one time.
  • 183-200 pairs packed per man hour.
  • Ability to ship e-commerce order out at the same-day before 4:00 p.m.
  • Downsized from 3 to 2 shifts.
  • No single employee downsizing.
  • 37% increase in productivity

Solution

Convert to Put to light Systems

  • The system fit perfectly for the customer.
  • It provided the capacity and the reliability they needed with further rooms to grow.
  • They can handle all the multi channel requirements with this in JUST one system.

Case 2 – Deal with Massive Workload

Before

  • Keihin Distribution needed to perform picking for a large number of orders (roughly 6,000 per day).
  • The company sought a highly efficient workflow built on the visualization of A products, B products, and C products based on logistical analysis of item hit rates.

After

Picking efficiency and inventory accuracy improved

  • Productivity improved such that the company can now process roughly 7,000 orders per day.
  • Picking speed increased after two conveyor lines were introduced for high hit-rate items (A product) to enable picking for two orders at a time.
  • The final conveyor is split into a line for B/C products (low hit-rate items) and an inspection line. This configuration has improved work efficiency.

Solution

Picking efficiency and inventory accuracy improved

  • The final result is a pick to light system linked to free conveyors that comprise two lines with identical flow rack and conveyor layouts for high hit-rate items (A products), and a conveyor with a mid-sized rack for low hit-rate items (B/C products).

Case 3 – Prevent Errors

Before

  • The company delivers to individuals; therefore, they needed to completely eliminate sorting errors.
  • The company required a system that can flexibly accommodate the different sizes, weights, and order quantities of the 10,000+ different products they handle.

After

  • AIOI Systems used information such as the number of item types per order, sizes, and shipping frequencies to determine whether to use the sorting system (Put to Light) using error-proofing gate light modules, or order picking (Pick to Light) using HHT. This resulted in high productivity.
  • Using error-proofing gate light modules not only prevents sorting errors, but also made it possible for anyone to sort.
  • Because the gates open toward the rear, the quantity displayed is not hidden, and the gates can be closed at the push of a button.

Solution

Applied use of Pick-to-Light (PTL) system & Projection Picking System (PPS)

  • First scan the shipping instruction QR code. Respective PTL gets illuminated displaying the quantity to be picked up.
  • After picking up the quantity displayed move it to the next processing location.
  • Using the Projection Picking System🄬 (PPS) displaying the work instructions for parts with designated locations. Illuminating work locations so that the operator can perform the work according to the instructions.
  • Once the work has been completed, transfer the materials to the assembly line.

Case 4 – Visible RFID for High-Speed

Before

  • Attached paper stickers to merchandise and containers by hand to each destination and instructed shipping.
  • The instructions are also handwritten.
  • Work to put and remove stickers by hand
  • Garbage is generated
  • Human error causes mis delivery

After

  • The reader / writer instantly prints the shipping address information on the smart card.
  • Carry out shipping operations smoothly because the container already contains the information
  • No more hassle of putting and removing shipping stickers!!!
  • Less waste and the containers can be kept clean
  • No confusion at the site due to unattached or duplicated stickers, and delivery mistakes caused by these have been reduced.
  • Display information can be rewritten. (Can be printed and erased repeatedly, so there should be cost benefits in the medium to long term.)
  • The route delivery order is described to improve the convenience of the driver.

Solution

What and How Smart Cards are used in such workflow?

  • AIOI Smart Cards have been attached to all folding containers used in the centre, and shipping information that was previously managed with stickers has been digitized. Initially, company used 4000 cards, but with the increase in the amount of merchandise handled, company bought 1010 new cards.
  • Specifically, the products picked up according to the order are loaded on the shuttle rack, and the reader / writer instantly prints the shipping destination information on the smart card. Information is already written on the container that comes out of the shuttle rack, so shipping operations can be carried out smoothly.
  • On the work side, operators no longer need to put on and remove the shipping stickers / labels. Garbage has been reduced and the container can be kept clean. There is no confusion at the site due to unattached or duplicated stickers, and delivery mistakes caused by these have been reduced. Although the initial cost was incurred when introducing it, smart cards can be printed and erased repeatedly, so cost benefits should come out in the medium to long term.
  • In addition, since the displayed information can be rewritten, the route delivery order has recently been described to improve the convenience of the driver. When using it for inventory replenishment or shipping request to neighboring branches, we write a QR code and operate it so that the recipient can scan it and know the next work process.