Case Studies – F & B

Case 1 – Error Prevention

Before

 
  • The company has difficulty increasing the number of operators, and so aims to increase operator productivity and reduce shipping mistakes.
  • In light of the time it takes to respond to complaints about shipping mistakes, the company wants to prevent operators from inserting items into the wrong openings.
  • The company does not want to use separate racks for drink crates and milk crates; they want to use the same racks for both.
  • The company wants to use the racks wherever they are needed in the warehouse due to volume and timing. They also want to store the racks in a different place when they are not being used.

After

 
  • Dramatic reduction of wrong-row insertion errors!
  • Affixing a different color of LED tape to each row prevents operators from inserting items into the wrong row.
  • The racks are movable, making it possible to use warehouse space effectively.

Solution

Put-to-light systems + LED Tape

  • Movable racks that prevent inserting errors in all directions
  • Blue, red, and green LED tape was affixed to the respective openings to prevent operators from inserting items into openings on the wrong row.
  • Partitions were installed to prevent operators from inserting items into the wrong opening in a given row.
  • The dimensions of the racks can be changed to accommodate both the drinks crates and the milk crates.
  • Casters were added to the racks, and the Ethernet junction boxes were replaced with wireless systems. Now, the company is free to move the racks anywhere in the warehouse.

Workflow

  • Wireless Put-to-light systems used for simultaneous sorting by multiple operators.
  • Use a handy terminal to select one of four colors to use, and scan the merchandise. The gross weight is displayed on the handy terminal.
  • The display panel for the block of the selected color lights up.
  • The operator inserts the merchandise into the opening illuminated by the light module and LED lamp, and pushes down the display panel.
Hardware Used

Case 2 – Increase Speed & Efficiency

Before

 
  • Work efficiency could not be improved because single-color light modules, which can only be used by one person at a time, were used for large shipments.
  • As a pass-through operation, delivery times are tight and work time is limited.
  • Medium sorting between cases and cartons/pieces is done by hand; only veteran operators are able to improve efficiency.

After

 

Our system successfully simplified data management and shortened the work time

  • When five people work simultaneously, each operator can process 2,400 pieces per hour, which successfully shortens sorting work time!
  • Five-digit light module displays for cartons/pieces make it easy to understand assorting quantities—even large assorting quantities for single stores—at a glance! This helps improve work efficiency.
  • Even beginners can perform the work with ease!
  • Adapting our system to small quantities of a diverse array of products successfully improved productivity and accuracy.

Solution

Use of Master of Supply Parts software package

Pairing a medium sorting system with put to light

  • We created a system that pairs medium sorting performed with wireless handy terminals with a put to light system.
Image
Hardware Used

Case 3 – Effective Use of Space

Before

 
  • Each vegetable requires a different opening size, so the company needed to be able to change the configurations easily.
  • The company was using another company’s Pick to Light System, but was unable to change shelf pitch easily; they had to remove lamps from openings to make the changes when new items were added.

After

 

Pitch change work now requires only half as many operators

  • Our light modules are easily removable without special tools, so pitch change work now requires only half as many operators as before.
  • Part-time operators involved in pitch change work are now assigned to shipping and inspection work, reducing lead time to shipping.

Solution

A pick to light system with light modules that facilitate pitch and location changes

  • We created a Pick to Light System with easily removable light modules that simplify the work of changing shelf pitch, which had been separate from daily shipping work in the past.
  • High-volume items required three-digit light modules, while others required only two digits.
  • Our system made it easy to change light modules in response to changes in shipping volumes.
Image
Hardware Used

Ready to know more about AIOI Products?

Get in Touch for solutions & services, as AIOI professionals has the expertise and experience to make sure your project is done properly, and your investments has a better return in future.

Know More