Prime Distribution Services
System Summary
Prime Distribution Services, a third party logistics provider based in Plainfield, IN, supplies their customers with complete supply chain solutions incorporating warehousing, cross-docking, packaging and multi-vendor freight consolidation.
Prime Distribution Services (PDS) definition of consolidation is relatively simple; vendors warehouse their product PDS’ facilities, PDS picks and packs their orders and combines them with other orders bound for the same destination. Many of PDS’s customers are smaller companies who ship large quantities of products at the retail level. PDS offers these companies cost effective distribution programs and allows them compete more cost effectively against larger companies who are able to ship full truckload volume to retailers.
The Challenge
As the industry changed, and PDS’s customers started to ship fewer single item full pallets and more mixed item pallets, the burden of picking and shipping became a time consuming task for Prime Distribution. PDS decided an automated solution was needed to process these picks and that better visibility and accountability was required to support their rapid growth.
Key Technologies
- Exacta Warehouse Management Software
- Exacta Warehouse Control Software
- Conveyor routing and sortation
- Marquee sign displays
- Event Director alerts
- Pick to Display
- RF handheld devices
The Solution
Prime Distribution Services selected the Exacta Warehouse Management System (WMS) following an initial installation of Pick to Display (PTD) technology in a pilot pick module solution. The ASAP team worked with Prime Distribution to define the functional requirements of the Warehouse Management Software, the appropriate picking technology, and the routing logic for cartons on the conveyor and sortation lanes.
Receiving
Operators using an RF handheld scanner, receive in pallets against expected receipts. If the product requires lot and expiration date tracking, the operator is prompted to enter the information. If the product is not lot tracked, the operator is not prompted. Labels are printed and applied to each pallet with unique container ids. Pallets are staged for putaway or cross dock processing.
Putaway
Using RF guns, operators scan pallets for putaway into secondary storage locations and based on rules set up in the Exacta WMS, are directed to the proper size storage location.
Picking
Orders with the same destination are grouped together to build a load by Customer Service personnel. The orders with an associated load number are downloaded to Exacta from the host system, Syspro. Using Ship Lane Scheduling, operators assign loads to available ship staging lanes.
Orders are evaluated to determine what locations the inventory should be picked from. The Warehouse Management System also uses custom logic for less than full pallet picks, to pre-cube those items into mixed item pallets to be picked and built.
Products are stored in one of multiple pick modules or in floor storage lanes. For items with primary pick locations in the pick module, pallets are grouped and released for picking using the wave option in Exacta Manager. PDS is able to view pallets that need to be picked and select them for release in the pick module. The wave module provides the ability for operators to build several waves in advance which are then automatically released in the pick module as pick operators complete the work from the prior wave. This design allows PDS to keep their pickers highly utilized. Through the wave screen PDS has visibility of a variety of information about the individual pallets on each wave. As pallets are processed, the wave screen updates in real time to provide processing statistics to the operator managing the area.
Pick to Display technology is used in the pick module to enhance picking productivity while maintaining order accuracy. As a wave is ready to be picked, the pick to display devices at the appropriate locations are illuminated. The devices display to the picking operators the quantity to pick, the lot code to pick as well as other item specific information. Pickers select the quantity indicated and press the button on the pick to display device to confirm the picks. Picked items are placed onto a conveyor and travel to the sorter.
Once at the sorter, the conveyor will be stopped and the Exacta Warehouse Control Software dynamically releases waves for sorting based upon predetermined logic including available lanes and product/lot rules. As the pallet is assigned to a divert lane off the sorter the packing list (with bar coded container id) is automatically triggered to print at the pick module supervisor workstation.
Each lane off the sorter has an overhead marquee device and that displays the pallet type to use, the quantity not yet diverted, the total quantity expected and the total “diverted” through the jackpot lane.
For items with primary case pick locations not in the pick module, operators use an RF gun for picking. The picking process directs the operator in sequence to locations containing the items that are required for that mixed SKU pallet.
Full pallet quantities of an item needed on an order are picked from secondary storage locations using an RF handheld device.
Pack
All pallets of picked orders are taken to one of the pack stations. At the pack station the items may be validated, the pallet is stretch wrapped (if required) and the shipping label with SSCC 18 number is printed and applied.
Stage and Load
After a pallet has passed through a pack station and has a shipping label it is moved to the staging lane for the load that order was assigned to at the start of the process. Operators with RF guns, scan to verify the pallet to the correct ship staging lane for the load. Once all pallets for all orders on the load are in the staging lane, the trailer load process can begin. Using the RF handheld, an operator is able to scan the dock door and each pallet to that door for loading. The Bill of Lading, Master Packing Slip and Shipping Manifest are all automatically printed out. As a final step to release and update the load as shipped to the host system, operators using the Ship Lane Scheduler to indicate actual departure of a load and transactions are sent to Syspo.
The Benefits
Provides visibility to information in real-time
The warehouse management system provides managers and lead personnel with the up to date information they need to process receipts and orders efficiently.
Increase in picking productivity
Having the products located within pallet flow rack in a pick module, allows operators to quickly walk to the picking location, pick the required item, place it on the conveyor and continue picking.
Reduction in quantity picking errors
With a scanner on the conveyor scanning each case and being counted as the item is diverted down the lane to be palletized, it is fast and easy to verify correct item quantities for a pallet.
The Future
Prime Distribution Services is enjoying the benefits and business advantages they have achieved through the implementation of the Warehouse Management System, Pick to Display and Warehouse Control System. Seeing the success of the system, Prime Distribution is in the process of adding another pick module to their Plainfield location and has plans to install the Warehouse Management System in their facilities in Mesquite, TX and Stockton, CA as well as future planned locations.
