Lane Automotive automates pick and pack

Location: Watervliet, Mich.
Size: 350,000 square feet
Number of SKUs: At any given time 110,000, counting all zones. Currently storing 53,000 in AS/RS with planned storage count of 77,000
Shifts: Operating 3 shifts weekdays with additional shifts as needed during peak season

Read the full feature article on the Lane Automotive distribution center here.

Lane Automotive, a Michigan-based wholesaler and distributor of aftermarket automotive performance racing parts and accessories, has steadily improved its DC systems and order fulfillment processes.

The first project was the installation of a multi-level pick module with pick-and-pass system directives in 2016, and more recently the addition of a robotic automated storage and retrieval system (AS/RS) for picking goods into shipping cartons, and then conveying them through a new automated packaging line, completed earlier this year.

The pick module and some manual pack stations remain in use for certain order/SKU profiles, but much of the volume is being processed in the new systems for automated pick and pack. The new project extended the mezzanine level to gain some processing space but did not include a building expansion.

Receive and replenish

Inbound shipments arrive at one of 15 receiving dock doors (1), typically as palletized goods, and from there are moved by lift trucks to a nearby receiving processing area (2), where inbound goods are checked and processed for conveyance into the robotic AS/RS, or for movement into reserve storage or two-level pick module (6). The receiving processing area has scales and equipment to verify weights and dims, as part of the quality control steps for the new material flow or exception handling.

There are two unique aspects of the implementation. First, rather than replenish the robotic AS/RS with its standard replenishment picking stations serviced by mobile robots, the systems integrator and Lane Automotive devised a replenishment loop with conveyor (3), and light-enabled workstations with 48 put/buffer locations. Goods are transferred here into totes for the Skypod system, checked for weight again, and then are inducted into the Skypod (4) at its “bin interface” entry point.

Pick and pack automated

Second, rather than picking primarily to totes at the presentation stations as in the pick module, the project created a carton erecting and induction system (5) that forms and places the correct sized shipping cartons into four put areas created next to each presentation station. Orders are picked into the cartons using pick-to-light and visual display directives, and when complete, the picker slides the completed order cartons onto take away conveyor, which moves the cartons up into the automated packaging line (7) on the DC’s expanded mezzanine level.

The automated packaging line has multiple subsystems, including automated document insertion, automated scanning and void fill dispensing, automatic carton sealing, and print and apply functions. Plans call for the pack out process from the pick module to merge into the automated packaging line at a later date.

The automated packaging line is on the expanded mezzanine level. Nearby on the same level are manual pack-out stations that remain in use for hazardous shipments, larger goods, or products with fluids or lubricants picked from the pick module, etc. But since there is reduced volume through the pick module with the new AS/RS, the new project converted some pack-out stations into order consolidation stations put-to-light walls (8), for orders that have some goods coming from the pick module, and other goods picked from the system. The DC also has some reserve storage areas and racking zones (9) to store various size items including performance tires, which are handled by lift truck.

Below the packaging lines on a sub-mezzanine level is a sliding shoe sorter (10) that routes goods to one of 18 dock doors (11). A space is available on the ground level for palletizing, as well as consolidation across eight put walls and staging for larger LTL and international orders. Most of the outbound shipments are parcels that are loaded into carrier trucks using extendable conveyor, though some palletized or larger goods are loaded with lift trucks.