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SUPPLEMENTS MANUFACTURER INSTALLS AWARD-WINNING FULFILLMENT SYSTEM
Starlight
International had two overriding objectives for its new health care
products distribution center: (1) incorporate the best equipment and
components available and (2) create a system that could easily expand as
the business grew. The fast-growing company was able to accomplish both
these goals in a streamlined 40,000 square-foot distribution center that recently
opened in Monterey, California.
Starlight International's vision is to do $300 million a year in the
United States and to expand internationally. It's well on its way toward
reaching that target. But at the same time, the rapid growth had put a
strain on the existing facilities.
The new Monterey operation represents a collaborative effort between
Starlight International and FloStor. "FloStor always has
been there for us," says Caroline Dollemore, Senior Manager of
Planning and Development for Starlight International. "As a result
of that relationship, we naturally turned to them when we bought this
building."
A Streamlined Flow
The Monterey distribution center was carefully designed to handle
today's requirements, while meeting tomorrow's growth needs. The center
is divided into five pick cells, all seamlessly connected by conveyors.
These pick cells can be further divided into any number of pick zones
depending on volume and picking method used--wave or batch.
The new center emphasizes simplicity and streamlined order flow.
All
orders are filled in individual totes, with each order averaging three
to four line items. The order fulfillment process starts in the express
conveyor lane at the initial picking station. The operator takes an
empty tote off an upper conveyor and begins filling the order on the
express lane. If the order is completed in that initial pick area, it is
placed on an adjacent powered conveyor. This leads to another powered
takeaway conveyor that transports the orders to the pack out/manifest
stations.
An interesting feature of the Monterey conveyor system is the
half-moon ball transfers in two of the main picking areas. These
custom-designed Hytrol units enable operators to easily transfer
the tote from one gravity pick line to another without lifting or
walking.
The main conveyor line carries the completed orders to the pack out
stations where they are weighed, scanned, manifested, and prepared for
delivery by UPS, Federal Express or USPS. All of these activities are
automated and computerized. This not only expedites the order-flow
process, but also eliminates paperwork. The empty totes then are placed
on the upper conveyor line for transport back to the first picking cell.
The streamlined operation works so well that orders received by 10
A.M. are often shipped that same day. "The distributors love this
fast turnaround," says Sue Kriegel, Manager of Distribution,
"and now they've come to expect it."
Ready for Expansion
The Monterey distribution center was designed with expansion in mind. As
Starlight International closes in on its $300 million domestic sales
goal, work stations can be expanded and pick lines double stacked as
needed. Importantly, this can all be readily accomplished within the
existing configuration with the facility remaining operational. The
company has high hopes for the new facility, expecting it to immediately
provide a minimum 50 percent increase in productivity.
First Runner-Up, Warehouse Magazine's Peak Performer Awards. See
article
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