Pomeroy Computer Resources |
SIC: 5045 |
Hytrol Distributor: KMH Systems (Cincinnati, OH)
Throughput Nearly Triples With New Conveyor System
Pomeroy Computer Resources has seen unit throughput
jump from 2,500 to more than 7,000 a week. System is designed to handle even
more growth.
Pomeroy
Computer Resources had a problem that a lot of companies would envy. The
company was growing so fast that it was pushing the limits of a distribution
facility built two years earlier.
Pomeroy is a provider of custom configured computer
systems and technical support. In 1995, it opened a brand new distribution
center in Hebron, Kentucky, just across the Ohio River from Cincinnati. But
by 1997, the company already had outgrown that facility, so it decided to
add another 70,000 square feet-20,000 square feet of which was devoted to
a new configuration and channel assembly center.
Configuration is at the heart of Pomeroy's business.
The company is widely known for its ability to configure business computer
systems to exact customer specifications-including all the hardware, software,
and peripherals that may be involved. Pomeroy also provides full technical
support for its systems.
Design of the new configuration center was a
joint effort between Pomeroy and KMH Systems of Cincinnati, a distributor
of Hytrol conveyor equipment. The design team focused on certain key objectives.
For one thing, they wanted the configuration technicians to be able to
concentrate on their primary job-providing value-added systems to the customer.
They did not want them to get bogged down in materials handling activities
like unboxing the computers in order to work on them-and then reboxing them
when they were done. This was what the technicians had to do in the existing
configuration center, a cramped 4,000 square-foot work area.
Pomeroy also wanted a system that would smoothly
and efficiently bring the computers (without the boxes) to the configuration
and quality assurance technicians at their workstations. And they wanted
a design that could be easily expanded or reconfigured without major disruption
to the operation.
The solution came in a simple but effective approach
utilizing basic Hytrol conveyor equipment. using powered "spool" and gravity
conveyors, Pomeroy Computer Resources has been able to achieve its major
objectives. The skilled technicians now can focus on what they do best. Boxing
and reboxing activities have been taken out of the configuration center and
relocated to the shipping area. In addition, Pomeroy can readily expand the
conveyorized system as needed.
Productivity has increased dramatically since
the installation. "We're now efficiently processing more than 7,000 units
a week, and that's at only about 30 percent capacity," reports Greg
Lorenzen,
manager of the configuration center. "Under the old system, we struggled
to process even 2,500 units at 80 percent capacity."
A Streamlined Process Flow
The material flow process at Herbron works flawlessly.
Computers to be figured, along with any components or peripherals required
for configuration or channel assembly, are moved form the warehouse to the
induction point just outside of the 20,000 square foot configuration area.
They are removed from their boxes and placed onto conveyorable ESD (electrostatic
dissipation) trays, which help control and minimize electrostatic
charges.
Each tray contains an identification tag that
corresponds to a shelf location in the induction area where the computer
boxes are stored. The box and the computer will be reunited at the end of
the order-fulfillment process.
The ESD trays are placed on a powered spool
accumulation conveyor (190-SPA) that leads into the configuration area. A
production coordinator at a central workstation diverts the trays down one
of four lanes in the configuration area. Lane selection is based on a number
of factors including the customer, nature of the work to be done, and particular
expertise f the technicians. In the future, Pomeroy plans to automate this
process through enhanced computer controls. It also plans to expand the number
of conveyor s and workstations in the configuration area.
After the technicians have completed the customized
configurations at their workstations, they place the trays back on the lane
conveyors that lead to a perpendicular takeaway conveyor. This powered unit
takes the configured units to the quality assurance area. Here technicians
work off three short conveyor lines, pulling on average one of every five
units for a thorough inspection.
Any orders not passing the inspection is sent
back to the configuration technicians for appropriate corrective action.
All others travel onto a takeaway conveyor that leads out of the enclosed
configuration section and onto the shipping area. Here the units are manually
diverted down one of four gravity conveyor lanes.
Operators at this final stage of the order-flow
process rebox the computer in the appropriate carton, paying careful attention
to match the computer identification number to the box I.D. The orders now
are ready for delivery to Pomeroy customers via surface parcel, air express,
or LTL.
The Engine for Growth
For a fast-growing company like Pomeroy Computer Resources,
the new conveyor system is an excellent fit. It responds effectively to today's
demand, while allowing for rapid expansion as business needs dictate. In
addition, the system is straightforward and easy to maintain, thus ensuring
maximum uptime. "When we do have a problem" says Lorenzen, "KMH Systems has
been there with quick and consistent service."
In the final analysis, says Lorenzen, the ability
to provide high-quality systems and support is the engine that will continue
to drive Pomeroy's growth in the future.
The Pomeroy Computer Resources DC
Computer units are take out of the induction
point outside of the configuration room and placed on ESD trays. The boxes
are shelved here, to be reunited with the computer at the end of the order
fulfillment process. A powered spool conveyor transports the computer and
related parts/peripherals past a production coordinator who diverts the trays
to the appropriate configuration line. After the configuration technicians
complete their work, they place the computer back on the conveyor lane, which
connects with the perpendicular powered conveyor. Orders then move to the
quality assurance area, where one of five units is pulled off for inspection.
Completed units travel on takeaway conveyors to the shipping area. They are
diverted to one of four gravity lines and repackaged in their original box,
ready for shipment.
A Closer Look At The Distribution
Warehouse
Company: Pomeroy Computer
Resources
Facility: Distribution Center
Location: Hebron, KY
Size: 210,000 square feet (total facility)
Employees: 150 (distribution center operations)
Members of Pomeroy Design Team: Eli Workum, Greg Lorenzen, Jim
Fiorelli, Brad Shouse
Product Handled: Computer systems
Throughput: 7,000 units per week
Shipment Method: Surface parcel, Air, and LTL
Conveyor Supplier: Hytrol Conveyor Inc., Jonesboro AR
Systems Integrator: KMH Systems, Cincinnati, OH |
Types of conveyors:
- Live roller
- Belt incline
- Gravity
- Skatewheel
- Spool
- Overhead paddle diverters.
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