Wilton Industries, Inc. |
SIC: 3469
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Systems Integrator: Conveyor Solutions, Inc. (Schaumburg, IL)
Throughput Jumps With New Conveyors
Integrated conveyor system combines with paperless
picking and WMS to help Wilton Industries reach new productivity levels.
Wilton
Industries is a company on a steady growth trajectory. Its four main
business units—the Wilton Enterprises line of baking and cake decorating
products, Rowoco kitchen utensils, the Weston Gallery of designer photo
frames, and Copco fine kitchenware—have all recorded big volume
increases over the past few years.
Inevitably, this kind of growth brings with it some operating
challenges—one of the toughest being how to keep pace with booming order
volume. The company is meeting that challenge at its Wilton Enterprises
unit at Woodridge, Illinois, with a streamlined new Hytrol conveyor system
from Conveyor Solutions, Inc. That system, combined with a new RF-based
paperless picking operation and a sophisticated Warehouse Management
System (WMS), is helping Woodridge achieve record levels of productivity—with
the capacity to achieve even higher levels in the future.
"Our primary objectives were to increase throughput and
accuracy," says Tom Gibadlo, Wilton's vice president of operations.
"Since the installation was completed in June of last year, we've
made great gains in throughput and now we're beginning to see some
significant improvement in accuracy as well." Gibadlo, Bill Mathews
(Wilton's director of logistics), and their team worked hand-in-hand with
Conveyor Solutions Inc. in designing and installing the new system.
Conveyor Solutions is a systems integrator and distributor of Hytrol
equipment based in Schaumburg, Illinois.
Upgrading and Improving
Prior
to installation of the new conveyor system, the Woodridge facility faced a
number of inhibitors to peak productivity. For one thing, none of the
existing conveyor lines in the picking areas were connected. Orders had to
be moved by hand around the facility to the appropriate pallets and then
loaded onto the trucks. This resulted in throughput levels that were less
than optimum. It also meant that shipping cartons were not being filled to
their optimum weight, which often translated to higher shipping costs.
The new operation addresses these problems. . .and more. An integrated
conveyor system—incorporating belt, gravity, sawtooth merge, and
horizontal accumulating units with the EZ-Logic feature—expedites the
flow of orders throughout the 143,000 square-foot facility. The conveyors
connect three picking areas for less-than-case picks, a separate case pick
module, and a mezzanine picking area for mail orders. All of these lines
flow into a computer-controlled sortation system, which sends the cartons
down the correct shipping lines.
Order fulfillment is quick and efficient in all of the pick areas. In
the full-case and less-than-case pick modules on the ground floor, an
automated RF system directs the picking activity, replacing the old
paper-based method. The order picker first scans the bar-coded shipping
label on the carton. The RF unit directs the picker to the right bin
location. The picker then scans the bin location to verify location
accuracy before proceeding with the actual order picking.
The workers complete picking in one zone before moving the carton on
gravity conveyors to the next zone. In the less-than-case area, when all
of the picks are completed in one line, the cartons are placed on powered
horizontal conveyors and moved on to the next picking module. There the
process is repeated until the order is complete.
When the orders are completely filled in the ground floor picking
areas, they are placed on a powered conveyor for transport to the tape
packing machines. Packing material is inserted into the cartons and the
case is sealed. The shipping carton then passes over a weigh-in-motion
scale that captures the carton weight for manifesting. Scanners direct the
cartons from the main picking areas and the mezzanine down four powered
takeaway conveyors with the EZ Logic accumulation feature and through a
sawtooth merge to the sortation area.
The sortation
system is a critical element of the Woodridge operation. It currently
processes 18 cases a minute and has the capacity to handle 30. The
sortation system diverts the shipping cartons down to the appropriate
shipping line. Several of these lines, called "fluid load
lines," extend directly into the outbound truck.
The last shipping carton of each order is diverted to a packing list
area. Here the carton is scanned and a packing list of the order is
produced and applied to the carton. With the packing list applied, the
shipping carton is re-inducted into the sorter via a re-circulation
conveyor and diverted down to the proper line. All in all, it's a
streamlined and efficient system.
Counting the Benefits
In
combination with the WMS and paperless picking, the new conveyors began
boosting productivity at Woodridge almost from the very beginning. Today,
throughput is up by more than 20% in the case pick area alone.
Importantly, the design allows for easy expansion of the pick modules and
sortation system if required.
In addition, the average weight of the parcels shipped is up from 13 to
19 pounds thanks to conveyor integration of the picking lines. This has
resulted in lower overall carton volume as well as a significant reduction
in shipping costs.
One other benefit bears mentioning here, too. The installation was
completed without a single shift having to shut down. "I credit Scott
Lee and his people at Conveyor Solutions for making this happen,"
says Gibadlo. "They worked closely with us to ensure that we had no
loss of productivity.
The Wilton Center
Completed orders picked in the
less-than-case pick lines on the ground floor move up on belt conveyors to
the taping and sealing stations. Orders in the case pick module are taped
and sealed on the ground floor before moving up. All of these cartons,
along with orders from the mezzanine, pass though the sawtooth merge
enroute to the sortation area. The sortation system diverts the shipping
cartons down to the appropriate shipping line. The new system enables
"live loading" of the trucks for added productivity.
Details on the Installation
Company: Wilton Industries Inc.
Facility: Distribution Center
Location: Woodridge, IL
Size: 143,000 square feet
Employees: 144 (two shifts)
Vice President of Operations: Tom Gibadlo
Product handled: Baking and cake decorating products, party goods.
Throughput: 8,000 cases/day
Types of conveyors: Horizontal power (EZ Logic and accumulating),
live roller, belt, sawtooth merge, gravity.
Control System: Allen Bradley PLC
Conveyor supplier: Hytrol Conveyor Inc., Jonesboro, AR
Systems Integrator: Conveyor Solutions Inc. (Schaumburg, IL)
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