Chain Reaction
A Extremely Versatile Supply Chain Gets Its Distribution Center Upgraded
Even though the 200,000 square foot distribution center of Christopher & Banks was able to provide its stores with quick fulfillment, the transportation expenses their methods' incurred were cost prohibitive. Additionally, there was a strong urge to reduce transportation expenses by repacking items to increase the weight of the boxes. The desire to repack a large percentage of merchandise strained the existing capacity and aging equipment. The facility relied on a very old, inflexible conveyor system, which was a source of chronic maintenance and other operational challenges. material handling is also frequently used in the warehousing and packaging processes.
In the face of aging equipment, an inefficient work flow, and a paper picking system, the company thought that it needed an upgrade to continue supporting just in-time delivery and direct to consumer fulfillment operations. Christopher & Banks had help from a material handling consulting firm but put the project on hold until Mike Tripp joined the team as the new supply chain and logistics manager. Tripp joined the team with the know-how and experience to make a plan for a more productive, energy efficient, and ergonomically sound solution that met throughput and budget restrictions. There are also some interesting conveyor systems systems that use lighted colors that can be quickly recognized to distinguish various types of items from each other.
The project was placed on competitive bidding and the contract was won in April 2009 by Intelligrated. The cost-effective proposal, which offered productivity gains at less than half the cost of other proposals, was put on a fast paced schedule for an August 2009 completion, before fall store deliveries began.
The Christopher & Banks facility's retrofit is made for a new linear flow that has a fulfillment process that's semi-automatic. Merchandise is inspected and the quality is checked in receiving areas, then delivered by forklift to staging areas. The operators utilize RF-scanning to upload all the new merchandise information into the pick-to-light system, where the product is put into an ergonomically-made combination conveyor and shelf support assembly. Distribution center workers add items to master cartons as they travel along an Intelligrated gravity conveyor. This semi automated fulfillment process represents an improvement over the legacy system, eliminating manual lifting and floor clutter and providing a safer, quieter solution that is quicker and more accurate.
Once individual store orders are complete, cartons are pushed onto a central take away belt conveyor to a two level Intelligrated motor driven roller (MDR) conveyor collection line. With features like zero pressure accumulation and run on demand independent zones, the conveyor decreases energy use and wear, removes product jams and allows the filling of the whole length of the conveyor. This allows the continuation of order picking that's independent of shipping activity. Cartons go on to a central merge and sorter to be moved to any of three shipping lanes. On each lane, the cartons are automatically sealed, weighed, and labeled at a work station then conveyed to a trailer directly at the doors of the shipping dock.
Other upgrades to the facility include a convenient overhead empty carton conveyor provided by Intelligrated. The facility produces up to 4 tons of empty corrugate every day, the reworked line for empty cartons directly routes corrugate into a container waiting outside to be sent for recycling.
Diana Ross - Chain Reaction
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