Chain Necklace
A Flexible Supply Chain Gets A Distribution Center Upgrade
The 200,000 square foot distribution center of Christopher & Banks had been supporting quick fulfillment to its branches, but their methods’ transportation expenses were cost prohibitive. Additionally, there was a strong urge to reduce transportation expenses by repacking items to increase the weight of the boxes. The need to repack a large percentage of the products strained the present capacity and aging equipment. The facility was dependent on an old and inflexible conveyor system that was also where operational challenges and lots of chronic maintenance came from. Conveyor and material handling systems are also utilized frequently in airports and freight handling businesses.
With the combined difficulties of an inefficient workflow, a paper picking system, and aging equipment, the company decided that in order to continue supporting just in-time delivery and direct to consumer fulfillment operations, upgrades were necessary. 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 with the experience and know-how to make a plan for a more energy efficient, productive, and ergonomically sound solution that satisfied throughput and budget constraints. 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 company put the project up for competitive bids and Intelligrated won it in April 2009. The cost-effective proposal, offering productivity gains for less than half of the other proposals’ costs, was placed on a schedule for a fast paced completion by August 2009, before fall store deliveries started.
The Christopher & Banks facility’s retrofit is designed for a new linear flow that has a semi-automated fulfillment process. Receiving areas inspect the merchandise, check the quality and forklifts then deliver them to staging areas. Operators make use of RF-scanning to upload the data of new merchandise into the pick-to-light system, where the product is then placed into an ergonomically designed combination of shelf and conveyor support assemblies. In the distribution center, workers add items to master cartons asthey move along the 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 finished, the cartons are pushed to a take-away conveyor belt onto a two-level Intelligrated motor driven roller (MDR) conveyor collection line. Features like run on demand independent zones and zero pressure accumulation, the conveyor lessens wear and power use, gets rid of product jams and allows for the whole length of the conveyor to be filled. With this, order picking can go on independently of shipping activity. Cartons proceed to a central merge and sorter where they are directed to one of three shipping lanes. On each shipping lane, cartons are automatically sealed, then weighed and labeled at a work station and conveyed directly into a trailer at the shipping dock doors.
Some of the facility’s upgrades include a convenient overhead empty carton conveyor given by Intelligrated. The facility makes up to 4 tons of empty corrugate on a daily basis, the reworked line for empty cartons moves the empty corrugate directly into a container waiting outside that is then sent out to be recycled.
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