Systems Integrator: Conveyors & Drives, Inc. (Atlanta, GA)
Keeping on the Growth
Curve New Conveyor System, coupled with
advanced technology, helps Tree of Life keep pace with growing
demand for its natural food products.
Since its founding in 1970, Tree of Life has enjoyed an
unparalleled record of success. From its roots as a regional wholesaler of
natural foods, Tree of Life has grown into the nation's leading marketer
and distributor of natural and organic foods, nutritional and dietary
supplements, and specialty foods. Today, the company has more than 6,000
employees and 15,000 retail customers.
Distribution
excellence has always been a core component of the Tree of
Life business philosophy. Strategically located across the
United States, the company's distribution centers typically
maintain in-stock positions of 95 percent on more than 30,000
SKUs—a performance few specialty foods distributors can
match.
Nowhere
is the emphasis on distribution excellence any more evident
than at the company's Southeast Distribution Center in Elkton,
FL. This modern 230,000 square-foot facility incorporates the
latest in RF technology, an advanced Warehouse Management
System, and sophisticated computer controls.
The center also features an integrated network of
Hytrol conveyor equipment that streamlines the flow of orders
from the picking stations through to the loading docks.
"We had several key objectives in
mind when we designed the Southeast Distribution Center,"
says Steve McCranie, senior vice president of distribution for
Tree of Life. "We wanted to increase overall productivity
and improve order turnaround time so that we could serve our
customers better and faster. This distribution center is
accomplishing those objectives-and the Hytrol conveyor system
plays a big part in that."
The
new distribution center, which went into operation in
September 2001, represents a team effort. Conveyors &
Drives Inc. of Atlanta installed the conveyor system and
related controls. The company is an experienced systems
integrator and distributor of Hytrol conveyor equipment. DCB
& Co., an Atlanta-based consulting firm, designed the
building and the materials handling system. DCB also served as
overall project manager for the installation. These two
companies worked hand-in-hand with Tree of Life's operations
staff, led by McCranie and Corporate Engineer Brian Daniel.
An Integrated System
The Southeast Distribution
Center incorporates a range of Hytrol conveyor and sortation
equipment—all seamlessly integrated to achieve Tree of
Life's throughput and productivity objectives. A key feature
of the system is the more than 3,000 feet of EZ Logic conveyor
in place. Hytrol's unique EZ Logic accumulating system
effectively controls the accumulation and release of product
from zone to zone.
The distribution center employs a wave picking approach.
The order-flow process begins at the DC's two main order-picking
areas. One is full case, the other split case (which Tree of Life
refers to as the "each pick" area). In the full-case
section, which also serves as a replenishment
area, cases are picked onto takeaway transport conveyors that
connect with two EZ Logic lines (190-ABEZ). These lines run in
parallel along the outer wall of the building toward a
sawtooth merge prior to entering the shipping area.
In the each-pick section, orders are picked from cases on
gravity flow racks and placed into shipping cartons or totes.
Horizontal belt sorters (SC model), located on each level of
the three-tier picking module, efficiently divert the cartons
to the proper pick stations until the orders are complete.
Completed
orders from the each-pick area merge onto EZ Logic lines and
head toward the sawtooth merge. En route, some are diverted to
a quality control spur. Prior to entering the sawtooth merge,
the cartons pass through strapping machines.
Dairy and
other temperature-sensitive products are picked in a separate
area adjacent to the three-tier picking module. These orders
move up an incline belt conveyor to a recirculation line where
they join the other cartons. Gapper belts regulate the flow of
all orders from the main picking lines and the recirculation
conveyor through the sawtooth merge. At present, the merge is
handling an average of 65 cartons a minute. It is engineered
to accommodate as many as 90 cartons a minute.
Orders emerge
from the sawtooth merge onto a single EZ Logic line. The
cartons then move through a servo-gap induction system, which
sets the proper spacing for them to pass through a scan tunnel
and toward the ProSort sorter. This high-speed sortation
system diverts the cartons down one of 12 lines. These include
the main lines for truck shipments and a separate line
reserved for UPS. There's also a line designated for wave
control as well as three lines used to replenish product.
At the
shipping lines, cartons are diverted onto a small segment of
gravity skatewheel that leads to a powered decline belt
conveyor. This configuration was specified over the more
common all-gravity option for an important reason: Tree of
Life places a premium on keeping all orders damage free during
the shipping process.
Technology
plays a key role in the smooth operation. Manhattan
Associates' advanced WMS, PkMS®, sets inventory and
allocation rules for each product. It determines what items
will be picked and where, which will be sent to QC, how orders
will be diverted, and so on. That information is communicated
to the computer controls, provided by Pyramid Controls. The
control system then interacts with the conveyor system, which
executes the orders. "The computer controls, coupled with
the conveyor system, help us create a streamlined order flow
and more effectively manage the wave picking process,"
notes Daniel.Productivity
and Reliability
Tree of Life
has been pleased with the performance of the Southeast DC to
date. Management reports that productivity levels continue to
improve as they become increasingly familiar with the system.
Overall reliability
of the conveyor operation—a critical capability for anyone
competing in the food distribution industry—has met
expectations as well.
Thanks to the
advanced technology in place, the new system also has given
Tree of Life greater visibility over the entire order-flow
process. Operators at the DC can spot potential congestion
problems anywhere in the facility and take preventive action.
One
other important aspect of the new operation bears
mention—the installation experience. Corporate Engineer
Daniel explains: "For a company like ours, the timeliness
of the installation is all important. When we set a date, we
expect that date to be met because delays in one DC can affect
the entire operation. Everyone involved in this installation
lived up to that commitment."
The Axxess Technologies Distribution Center
Product
flows smoothly and efficiently through the 230,000 square-foot
DC. Order processing begins in the full-case picking section
(which also serves as a replenishment area) and in the
"each pick" section. In the three-tier each pick
section, SC sorters divert the cartons to the appropriate pick
stations until
the order is complete. Cartons move out of the picking areas
on powered conveyor with the EZ Logic accumulating feature.
Some are diverted to QC for quality check. All cartons from
the main picking areas proceed toward a sawtooth merge where
they are joined by orders from dairy, which move on the
recirculation line. The cartons move through the sawtooth
merge, go through a scanning tunnel, and then move onto the
ProSort sortation line. The ProSort diverts the completed
orders down one of the shipping lines or down lines reserved
for replenishment or future wave management.
Snapshot
of the Operation
Company: Tree of Life Inc.
Facility: Southeast Distribution Center
Location: Elkton, FL
Size: 230,000 square feet
Employees: 100
Key Personnel: Corporate Engineer Brian,
Daniel, Senior V.P. Distribution Steve McCranie
Product Handled: Natural food products
Throughput: 60-65 cases/minute (capacity 90 cases/minute)
Types of conveyors: Horizontal power (ACC and ACZ models),
EZ Logic (ABEZ), gapper belt, sorters (SC and
Pro-Sort), sawtooth merge, incline belt (RBI),
gravity.
Project Management: DCB & Co., Atlanta, GA
WMS: PkMS, Manhattan Associates
Controls: Pyramid Controls, Inc.
Conveyor Supplier: Hytrol Conveyor Inc., Jonesboro AR
Systems Integrator: Conveyors & Drives, Inc., Atlanta,
GA
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