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Tag: Knapp

Warehouse Automation Quadruples Output

Posted on by David Priestman

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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Automation Helps NEXT make Delivery on Time

 

Automation Helps NEXT make Delivery on Time

Posted on by David Priestman

Leading fashion and homeware retailer, Next plc recently invested in a brand-new DC near Wakefield, connected to existing facilities by a link bridge. Looking to replace its legacy split tray sorter in order to increase throughput and reduce order-processing times, Next selected the AutoPocket sortation solution from KNAPP for its new warehouse.

AutoPocket is the latest generation of KNAPP’s pocket sorter technology, which arranges suspended pockets of goods into the precise sequence required for dispatch. “The key benefit of AutoPocket,” explains Craig Rollason, Managing Director of KNAPP UK, “is that it enables items to be deposited precisely and fully automatically anywhere in the warehouse, while moving at full speed. The ability to release items without needing to stop, or even slow down, makes the system incredibly fast.”

Every second counts

With Next promising next-day delivery for orders placed by 11pm, rapid order processing is critical. The AutoPocket system transports pockets with single-item orders directly to the packing stations, while those with goods from multi-line orders are sequenced by the system’s matrix sortation algorithm.

Two challenges, one solution

In the new DC, the KNAPP team has solved two challenges with one solution. While two AutoPocket modules consolidate and sort e-commerce orders highly efficiently, a third module handles sortation in the goods-out area. Combined with intelligent software, AutoPocket optimises the flow of goods for Next from picking all the way to shipping.

The two order-processing modules handle 15,000 items per hour, while the outbound module sorts 5,000 parcels per hour. In total, the AutoPocket system at Next features 32,300 pockets and processes around 240,000 items a day. The savings for Next, compared to a traditional cross-belt sorter, amount to 35% in weekly personnel hours. “In addition to reducing order-processing times,” says Craig Rollason, “using a single technology obviously secures benefits in terms of ease of maintenance and spare parts availability.”

Automated tote store

KNAPP has also supplied an OSR Shuttle automated store as part of its solution for Next. Containers from the store are automatically conveyed to one of 20 pocket-loading stations – 10 for each of the order-processing AutoPocket modules – where up to 1000 items per hour are taken from the totes, scanned and loaded into an automatically supplied pocket. From here, pockets are forwarded to the module distributor, which allocates them to one of the AutoPocket modules, balancing the workload between them to maximise throughput.

Buffer pocket storage

In the order consolidation area, each of the two modules has 14 buffers across two levels, where pockets of individual items are stored temporarily until all parts of an order have been processed and consolidated. Completed orders are automatically diverted from the rotating buffer to the six packing loops by the warehouse control system. Here, the pockets release their contents automatically at one of 240 chutes, which slide them to 60 packing stations. Employees pack all the items in an order into a polybag and these parcels are then fed onto a conveyor that transports them to the outbound sortation system.

Outbound sorter

Packed customer orders are inducted into the third AutoPocket module at one of six loading stations. The parcels are then sorted and distributed across 40 courier-specific drop-off points via the outbound sortation loop, from where they are shipped to customers worldwide.

“We are delighted to have delivered this successful project for Next,” comments Craig Rollason. “The AutoPocket is an incredibly versatile technology. As well as the order-fulfilment and outbound sortation tasks performed at the South Elmsall DC, AutoPocket can act as a highly efficient solution for processing returns. In addition, its modular construction means that the system can be scaled flexibly by adding sorter modules as volumes grow.”

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Fashion Retail Fulfilment Centre

 

MultiScan Master Data Solution Available

Posted on by David Priestman

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.”

Mission Zero Touch Robotics

Posted on by David Priestman

Cost pressures, lack of space and personnel shortages are major issues needing a solution. One key to solving these issues is intelligent robotics. KNAPP’s innovative robot solutions help lower costs in logistics processes while increasing shipping capacity. KNAPP calls this new approach zero-touch fulfilment.

The goal of zero-touch fulfilment is to increase the degree of automation while minimizing the number of manual work steps, allowing employees to work efficiently and be relieved from physically demanding and repetitive tasks. At LogiMAT in Stuttgart, Germany, KNAPP presented technologies that help companies meet these goals.

There is no zero-touch fulfilment without robotic picking. KNAPP’s Pick-it-Easy Robot (pictured) will pack and pick diverse items into different containers in a live demonstration. AI-based object recognition and grip point determination allow the robot to handle a wide array of items. The intelligent KiSoft software suite functions as the brain of Pick-it-Easy Robot. It is used to design made-to-order software solutions for all processes and across all levels.

Autonomous mobile robots (AMRs) handle in-house transport jobs and offer many benefits that conventional conveyors simply cannot provide. After being configured, which is quickly accomplished, they move about freely and independently. They don’t require any changes to the warehouse and the fleet can be expanded rapidly when there are more transport tasks. AMRs are versatile and can be used for transport from goods-in to the storage system, cross docking and supplying work stations. One of KNAPP’s series of AMRs, the Open Shuttle Fork, handles the transport of pallets automatically, space-effectively and flexibly.

These autonomous mobile robots are controlled by the intelligent fleet control system in the KiSoft suite. The travel paths and processes of the AMR are easy to model and adapt in the software. KiSoft functions like a navigation system with specific route planning, analogous to the GPS in a car, and its obstacle detection ensures complete safety for people and equipment.

The best automation solution is only as good as its master data. In order for robots, shuttles and the like to work in a way that creates value, they need good-quality master data. This is exactly what MultiScan does best: collect high-quality master data, which is then saved by the software KiSoft Genomix. MultiScan easily and precisely captures morphological data, such as the volume or weight of items as well as quantities, stacking data, EAN barcodes and much more. The software solution KiSoft Genomix digitizes all the relevant item attributes, from their weight, dimensions and packaging type to their contents, centre of gravity, tilting behaviour and much more. This type of information is critical for smooth operation in the robotic warehouse and is what a robotic system needs to precisely process and handle various types of items.

Even the smallest items, such as jewellery, watches and their parts need to be securely stored. For this application, KNAPP offers the InduStore, which stores and handles items up to the size of a shoe box and up to 5 kg (11 lb) as standard. The InduStore uses its intelligent image recognition system to automatically identify each item. A conveyor brings small items to the robot, which picks them up and places them on the shelves in a compact, space-saving way.

For today’s warehouse logistics, three areas of expertise make all the difference: machines and robots, service and consulting, and finally, software. Each of these areas can of course stand alone; however, when combined, they provide an incredible advantage. This is exactly the combination KNAPP focuses on. This approach using integrated intelligence connects all the disciplines to provide customers with an all-in-one solution. For example, the KiSoft software configures the AMRs, so they go where they are needed, and also trains the KNAPP Pick-it-Easy Robot picking robots so they continually improve. It’s quite an impressive interplay of robots and software. With its business intelligence products, KiSoft provides the information needed to make strategic decisions. KNAPP has modules in KiSoft for resource planning, data analysis for strategic decision-making, predictive maintenance and life cycle management.

Safe Access Issues for Overhead Conveyors

Posted on by David Priestman

The LOBO System, a leading provider of modular access solutions, has recently supported KNAPP, a global automation and logistics company, with a safe access issue for overhead conveyors.

The LOBO System provided a customized bespoke solution that addressed safety concerns and increased the efficiency of the conveyor systems.

KNAPP faced the challenge of providing safe access for maintenance and inspection of their overhead conveyors. The LOBO System provided a modular access solution that allowed for safe and easy access to the conveyors without disrupting the flow of operations. In addition, the solution included customizable and long staging platforms, making it easy for engineers to access the conveyors.

The LOBO System’s solution not only addressed the safety concerns but also increased the efficiency of the conveyor systems. The modular design allowed for quick and easy installation, reducing downtime and increasing productivity. The solution was also designed to be easily reconfigurable, allowing for future changes to the conveyor systems.

The product is designed to improve safety, reduce labour costs, and increase efficiency for businesses in the automated distribution industry. It is the perfect solution as the system is lightweight, easy to transport and can be assembled by just one person with no tools required.

“We are thrilled to have supported KNAPP in resolving their access issue. Our modular access platform solutions are designed to meet each customer’s specific needs, making it easy to address safety concerns while increasing efficiency,” said Tom Bokros, Senior Technical Sales Engineer at LOBO Systems.

The LOBO Advanced Platform System is a modular maintenance work platform that offers safe working at height configurable to any shape. It is perfect for accessing maintenance areas, conveyors, facilities and machinery.

The KNAPP Group is a global provider of intelligent automation solutions for intralogistics and manufacturing, specializing in healthcare, fashion/apparel, general retail, food retail, industry and service.

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