Warehouse Automation Quadruples Output

Third party logistics operator DSV has implemented a warehouse automation solution at its distribution centre in the Netherlands that has increased output by 300 per cent without needing additional personnel.

The omnichannel fulfilment solution from KNAPP has transformed the company’s existing 60,000 m² warehouse in Venlo, enabling DSV to process fashion and sports orders rapidly and efficiently for a well-known sports goods manufacturer.

Same-day and next-day delivery

On an average day, around 10,000 orders and 100,000 items are shipped to retail, wholesale and online customers across Europe from the facility with same-day and next-day service levels. The solution provides a high degree of flexibility to handle the peaks typical of the fashion sector, while also ensuring sustainability through an automated carton-closing system to optimise shipping volumes.

Goods entering the warehouse are repacked in containers or cartons at the 14 decanting stations, with some being stored on pallets in high-bay racking. The heart of the system at Venlo is KNAPP’s Evo Shuttle, a small parts warehouse with over 257,000 locations for plastic containers and cartons, which are stored triple deep in the 19-level store. A total of 361 shuttles operate within the system, retrieving items on demand and conveying them to the picking stations.

Volume-optimised shipping

Fulfilment is carried out at one of 16 goods-to-person workstations from KNAPP’s Pick-it-Easy series, where orders are assembled directly into shipping cartons supplied by an automatic carton erector. There are a further 28 workstations for value-added services and manual packing. After order assembly and before being conveyed to the 14 shipping ramps, the height of each shipping carton is adjusted to suit its contents and a shipping label is applied in a process that is completely automated.

Warehouse Automation

In addition to storage, retrieval and picking, the Evo Shuttle store takes care of order buffering and sequencing of completed orders. The whole solution is controlled by KNAPP’s KiSoft software, which interfaces with DSV’s inventory control system to ensure that all processes run smoothly and without errors. This software combination takes care of the entire flow of goods in real time, inventory management, all the product master data, order release, quality checking and document insertion. DSV also chose to have a resident service contract with KNAPP, so that engineers are permanently on site to ensure maximum system uptime. See the solution in action here.

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MultiScan Master Data Solution Available

Knapp, leading technology partner for value chains, is making its MultiScan master data capture system available to customers through short-term rental or outright purchase.

MultiScan is an intelligent and customisable master data capture solution. As well as acquiring article dimensions, MultiScan features integrated weight recording and can also capture other data such as fragility and stackability. The solution records all the data needed to optimise the utilisation of storage space and the efficiency of fulfilment operations.

“The MultiScan system can be particularly beneficial for companies handling seasonal or promotional items of stock,” explained Ben Carroll, IT Business Development Manager for Knapp UK, “as well as for retailers or 3PLs working with multiple vendors, smaller warehouse operators looking to boost efficiency in their e-fulfilment operations or organisations needing to capture article data for robotic systems.”

Maximum efficiency

As well as enhancing manual warehouse operations, capturing accurate master data is essential for automating material flows and achieving maximum efficiency through digitalisation of work processes. MultiScan automatically records all relevant data for an application, transmitting the information to the WMS or ERP system to enable optimal warehouse management. By maximising space utilisation – in totes, on shelves and in racking – and optimising the efficiency of packing operations by fitting more items into each carton or bag, MultiScan enables warehouse operators to achieve environmental benefits and lower transport costs. In addition, improving fulfilment efficiency – by requiring fewer visits to each location and fewer tote retrievals – means shorter picking times for both automated and manual systems, thereby improving the customer experience.

Accurate and versatile

MultiScan is suitable for a wide range of articles and records data with consistent accuracy. Optional precision scales and digital callipers enable measurement of smaller items, starting at 0.01mm and 0.5g. Another accessory, SCANtape, allows wireless measurement and identification of goods sized up to 3m. Further accessories include a bar code scanner and an industrial camera for high-resolution product photos, which can be directly interfaced to merchandising systems. An optional cart and battery mean that MultiScan can be used for mobile operations for up to 16 hours between charging, with the advantage that a 1-hour charge returns the battery to 80% capacity.

Intuitive operation

Featuring intuitive design, MultiScan enables rapid operation and avoids the need for lengthy training. Items can be placed anywhere on the measuring plate and data is captured quickly and automatically at the push of a button. The design is rugged and ergonomic, making it simple to use even when wearing gloves. “The solution’s software is compatible with any end device,” added Ben Carroll, “as well as with various interfaces and all common operating systems. MultiScan is also compatible with KNAPP’s AI-enabled KiSoft Genomix software in order to capture additional attributes and accelerate the process.”

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