THE LIVE STORAGE COMPANY
PRESS RELEASES 2007
LSC07/05: GO LIVE FOR PERFORMANCE PICKING (24 May 2007)
LSC07/04: FIRST IN, FIRST OUT AT FCC EUROPE WITH SPAN TRACK
(8 May 2007)
LSC07/03: PICK DENSITY AND EFFICIENCY IMPROVED AT WEBASTO
(27 March 2007)
LSC07/01: SORTEX IMPROVES LINESIDE PICKING WITH LIVE STORAGE
(10 January 2007)
SELECTED PRESS RELEASES ISSUED DURING 2006
SELECTED PRESS RELEASES ISSUED DURING 2005
BACKGROUND INFORMATION
CONTACT DETAILS
BACK TO CLIENT PRESS RELEASES
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PRESS INFORMATION (TOP)
Issue Date: 24 July 2007
Ref: LSC07/05
GO LIVE FOR PERFORMANCE PICKING
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Warehouse managers wanting to increase storage capacity or picking performance are often tempted by big-budget solutions that involve automation, computerisation and complexity. But keeping it simple can be just as productive and much less expensive. One way to make gains with modest outlay is to replace static pick faces with gravity fed live roller tracking such as Span Track from The Live Storage Company.
With gravity fed live storage, static shelving is replaced with sloping roller beds so that items simply roll down from the high to low end. This makes live storage ideal where first-in, first-out picking is required because there is a continuous flow of items from the rear to the front of the picking zone. Static storage offers no such guarantees because the picker can generally choose the item to retrieve. Live storage is also ideal for volume picking operations because items are always presented in the ideal position for convenience and efficiency. Picking rates are increased and more picks in the same shift means lower costs.
Because pickers do not need to reach into the storage area no space is required above and beside items. Additional tracking can be installed so that more of the available space or volume is utilised. Vertical spacing is dictated only by the maximum height of the items being picked. Up to 25 per cent more storage is possible in the same volume. Live Storage Company customer Sortex, the global leader in optical sorters for food commodities, reduced the space occupied by lineside storage in sub-assembly production areas by around 10 per cent by installing Span Track.
The best live storage equipment allows conventional static pick shelving or pallet racking to be converted very quickly by slotting ready-made units between, rather than on top of, first and second level beams to create the maximum possible picking space. This is often achieved without repositioning the racking which means productivity gains can be introduced quickly with minimal cost or disruption to ongoing operations. Ready-made units can be installed in about one third of the time taken to fit traditional live storage beds. Automotive component manufacturer Webasto Roof Systems improved storage density, increased picking efficiency and introduced better stock rotation in the warehouse at its factory in Birmingham by installing Span Track modules to convert static pallet locations into dynamic live picking faces.
There is a choice between plastic and steel roller track. Plastic may appear more affordable but it can be unreliable in all but the lightest duty applications which can add to maintenance and replacement costs. Steel units like Span Tack, on the other hand, are generally more robust and reliable which means less maintenance and lower overall cost of ownership. The best steel systems are designed to take the abuse of busy warehouses and assembly plants. Their full-width rollers ensure total support for cartons with up to 300 per cent more product contact than traditional plastic wheel tracking. This can be useful for heavier items and helps reduce snagging to maintain throughput and increase overall picking productivity.
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PRESS INFORMATION (TOP)
Issue Date: 8 May 2007
Ref: LSC07/04
FIRST IN, FIRST OUT AT FCC EUROPE WITH SPAN TRACK
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Automotive component manufacturer FCC Europe Limited has improved small component picking efficiency and first in, first out stock rotation at its factory in Milton Keynes through the introduction of dynamic live picking based around full-width roller Span Track modules from The Live Storage Company. The new installation was devised by The Live Storage Company to replace inefficient steel shelving and conventional racking that no longer provided an adequate solution to FCC Europe’s requirements.
“We wanted to improve stock rotation and introduce first in, first out picking,” says Mohammed Tanwir, Logistics & Purchasing Supervisor at FCC Europe Limited. “We knew we could do better than our existing facilities and The Live Storage Company provided a solution that helped us achieve our objective.”
Part of a global supplier of automotive transmission components, FCC Europe manufactures motor cycle and scooter clutches for the European market at the factory in Milton Keynes. The company had previously been stocking ten different spring components in boxes on steel shelving and conventional racking in its production stores but recognised this had limitations. The area took up a relatively large space, it was difficult to identify items on the shelving and there was no easy way of enforcing good first in, first out stock rotation.
One of FCC Europe’s managers saw dynamic live picking in action at another factory and the company invited The Live Storage Company to propose a similar solution for its own requirements. The Live Storage Company devised and built an installation based around its modular Span Track system to create a single bay of live storage adjacent to the existing production store.
The frame for the installation was created by The Live Storage Company using standard racking components. The company then supplied and fitted the Span Track units in predetermined lengths and widths matched to the dimensions of the frame and the size of the boxes containing the springs. The units were simply dropped into position, supported by the beams, to create a picking face with the maximum possible density. Vertical spacing was matched to the height of the boxes so that the maximum number of picking points could be installed in the face.
The completed installation ensures maximum storage and picking capacity on the minimum possible floorspace footprint. It incorporates 27 Span Track units, each holding up to ten boxes, arranged on four levels. Each track is marked and colour coded so that different components can be identified more easily for simpler picking. Staff can see what is on the shelf and complete their picks quickly and efficiently.
Items are replenished at the rear of the racking and fed by gravity down the shallow rollered incline of the Span Track module to the front face. They are presented at the optimum position for picking so that staff do not need to stretch to reach them. Because the width of each Span Track unit is matched to the dimensions of the boxes, items are presented singly and in sequence to the pickers. This has helped FCC Europe to introduce better control of first in-first out picking stock rotation.
The installation has provided FCC Europe with a highly efficient storage and picking for its spring components. The company can now store all of its spring components with complete picking selectivity. Incoming supplies are now placed straight onto the racking when they arrive at the factory to eliminate unnecessary storage and handling tasks. The company plans to store and pick bearings and similar small components in the same way in the near future.
“We now have FIFO and our staff can see what is on the shelf,” says Mohammed Tanwir. “Picking is more efficient and economical.”
Span Track is designed to take the abuse of busy warehouses and production areas. Units are manufactured from tempered aluminium rollers with full-length axles mounted on durable galvanised steel side channels which makes them extremely strong and robust. Full-width rollers ensure total support for cartons, bins and components with up to 300 per cent more product contact than traditional plastic wheel tracking. This also reduces the risk of items snagging which means that material flow is maintained and there is no loss of productivity. The simple drop-in design ensures the units can be installed easily without tools.
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PRESS INFORMATION (TOP)
Issue Date: 27 March 2007
Ref: LSC07/03
PICK DENSITY AND EFFICIENCY IMPROVED AT WEBASTO
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"right-click-and-save" the linked image)
Automotive component manufacturer Webasto Roof Systems has improved storage density, increased picking efficiency and introduced better stock rotation in the warehouse at its factory in Birmingham by installing highly efficient full-width roller track Span Track modules from The Live Storage Company to convert static pallet locations into dynamic live picking faces.
“We wanted to use the space in the warehouse more efficiently,” says Robert Jarman, Operations Director at Webasto Roof Systems. “By introducing the Span Track modules we have improved picking efficiency and probably tripled the storage density in the areas we have reconfigured.”
Webasto AG is a family-owned business based in Germany that develops and manufactures products and systems for fresh air, heating and air-conditioning in vehicles. The company was founded in 1901 and produced its first sunroofs in the 1930s. It continues to invest in research and development to deliver innovative solutions that are targeted at its customers’ demands.
When the company reviewed component storage and handling operations at its Birmingham sunroof factory it recognised the need for improvement. Webasto produces an extensive range of standard products and derivatives and must stock a large number of components to maintain production. It also supplies spares for older products and the ability to pick efficiently is important to overall customer service. The company was storing items in conventional pallet racking but recognised that this was an inefficient use of the available space which did not support good stock rotation or productive picking. Items were picked and replenished from the same side of the racking which meant that components at the front would always be selected before those behind. Space had to be left on the front of the pallet for replenishing stock which meant that the density of items at the picking point was always low. Finally, staff had to lean or stretch to reach items at the back of the pallet or shelf which was inefficient, inconvenient and unproductive.
“Storing items on pallets does not lend itself to quick picking or using the oldest items first,” says Robert Jarman. “Our plan was to get rid of pallets and pick from the front face so that we could improve stock rotation and density.”
After assessing a number of options and potential suppliers, Webasto selected The Live Storage Company’s modular Span Track live roller track system. The Live Storage Company supplied the Span Track units in predetermined lengths and widths matched to the dimensions of the existing racking and the boxed items being stored. Webasto reconfigured four pallet locations with Span Track units on four levels to create 40 live picking tracks. This was achieved by repositioning the existing cross beams and adding new ones to support the Span Track units. Vertical spacing was matched to the height of the boxes so that the maximum number of picking points could be installed in the existing face. The Span Track units were then simply dropped into position, supported by the beams, to create a picking face with the maximum possible density.
“Increasing storage density was key,” says Robert Jarman. “There is no wasted space. You can’t get the same density with pallets and racking.”
The new picking zone accommodates lightweight boxed plastics and metal components used in Webasto’s manufacturing process. Items are replenished at the rear of the racking and fed by gravity down the shallow rollered incline of the Span Track module to the front face at the optimum position for picking so that staff do not need to stretch to reach them. Because the width of each Span Track unit is matched to the dimensions of the boxes items are presented singly and in sequence to the pickers. This ensures that Webasto can maintain first in-first out picking stock rotation. Another advantage of live storage is that staff can pick items whenever they need without being hindered or obstructed by replenishment staff who will always be working on the other side of the racking in a different aisle. This helps maintain the integrity of the operation and eliminates bottlenecks so that productivity and efficiency are optimised.
Webasto recognises that goods arriving in the warehouse must be transferred from pallets to the live storage tracks but the time and costs involved are offset by improvements in picking efficiency and productivity. The previous practice of pulling down full pallets from higher locations to the picking face has now been replaced by a streamlined replenishment process.
“Span Track makes life nice and easy,” says Robert Jarman. “We can pick what we want, when we want.”
Span Track is designed to take the abuse of busy warehouses and production areas. Units are manufactured from tempered aluminium rollers with full-length axles mounted on durable galvanised steel side channels which makes them extremely strong and robust. Full-width rollers ensure total support for cartons, bins and components with up to 300 per cent more product contact than traditional plastic wheel tracking. This also reduces the risk of items snagging which means that material flow is maintained and there is no loss of productivity. The simple drop-in design ensured the units could be installed easily without tools and so that Webasto could convert the old installation for new dynamic live picking very quickly.
“The Span Track units are very light and very strong and it was no trouble to install them,” says Robert
Jarman.
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PRESS INFORMATION (TOP)
Issue Date: 10 January 2007
Ref: LSC07/01
SORTEX IMPROVES LINESIDE PICKING WITH LIVE STORAGE
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Sortex, the global leader in optical sorters for food commodities, has increased throughput and reduced lineside storage space in sub-assembly production areas by replacing static shelving with highly efficient full-width roller track Span Track units from The Live Storage Company. The changes have helped the company to improve efficiency, reduce product lead times and increase responsiveness to customer demands.
“Our production areas are now even more efficient and better organised than before and we have saved around 10 per cent of the space,” says Campbell Dixon,
Manufacturing Engineering Manager at Sortex. “The Span Track units are easy to install and we made the changes without any disruption to our ongoing operation.”
Sortex has manufactured high performance optical sorters which detect and remove defective product and foreign material from food commodities such as rice, grain, coffee, fruit and nuts since 1947. The company now supplies customers in more than 100 countries and has over 20,000 installations worldwide. It employs 180 people at its factory in London and won both the Queen’s Awards for Export and Industry in recent years and the UK National Business Award in 2004.
The company is highly focused on customer service and recently reviewed its manufacturing operations to reduce product lead times and increase factory throughput so that it could be even more responsive to customer demands in this highly competitive industry. It recognised that manufacturing products more quickly and with greater agility would help add value to its overall offer.
“How we manage materials was part of the overall project,” says Campbell Dixon. “So we looked at materials handling, lineside handling and how we replenish production areas.”
Sortex identified component handling and picking as areas where it could make improvements, with initial focus on sub-assembly production. Previously components for sub-assemblies were stocked in shelving mounted on conventional pallet racking before being picked for production. This limited item selectivity and constrained the flexibility required to manufacture and assemble complex machinery. Converting these areas for live picking offered the potential for greater efficiency through simpler picking, increased component availability and tidier storage with reduced overall footprint. Sortex chose Span Track because of its ease of installation and robust performance.
The Live Storage Company supplied a number of Span Track units in lengths and widths specified by Sortex so that they could be simply slotted into the existing racking frames to convert an area used for storing up to 60 different components. The simple drop-in design ensured the units could be installed easily without tools and allowed Sortex to convert the old installation for new dynamic live picking very quickly.
“We chose Span Track because the equipment is easy to install,” says Campbell Dixon. “They arrived on a pallet in the correct lengths and all we had to do was slot them into place in the existing frames. There was minimal disruption to our ongoing operations and we completed the task in around half a day.”
With the converted installations components move under gravity from the rear of the installation to the front where they are presented to production staff at the optimum position for picking. This eliminates the need to walk or reach to pick items and also helps keep the production area clean and tidy. The configuration of the storage area ensures production and picking staff can access components whenever they want and without disruption from replenishers. Conversely, replenishment can be maintained without entering the production area. Live storage also allows pick faces to be configured more closely to the dimensions of items which are presented individually and in first-in, first-out sequence for better quality control and stock rotation.
Sortex has reduced the space occupied by the area and improved supply of materials to the lineside. The company estimates that it has saved between 10 and 20 per cent of the space compared with the previous installations which did not use live racking. A more significant but less tangible benefit is that the company now has a much better organised production environment where everything is in its place. This has helped to reduce picking times, optimise inventory levels and generally enhance the agility of the manufacturing process so that it can be more responsive and flexible to customer requirements.
Reliability is essential because any failure in materials flow can disrupt the overall manufacturing process. Span Track is designed to take the abuse of busy production areas. Units are manufactured using tempered aluminium rollers with full-length axles mounted on durable galvanised steel side channels which makes them extremely strong and robust. Full-width rollers ensure total support for cartons, bins and components with up to 300 per cent more product contact than traditional plastic wheel tracking. They also reduce the risk of items snagging which means that material flow is maintained and there is no loss of productivity.
“Another reason we chose Span Track was because the rollers support weight across the full width of the box and not just on the edges which is more robust and reliable,” says Campbell Dixon.
Sortex has now ordered more Span Track units to reconfigure additional areas of the factory for live storage to achieve similar benefits.
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BACKGROUND INFORMATION (TOP)
The Live Storage Company offers flexible order picking and storage solutions based around the modular Span Track range of full-width roller carton flow track. The company provides consulting, installation and engineering support services to ensure customers achieve the maximum return on their investment.
Alternative images available on request.
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For further press information, please contact (TOP):
Nick Tyler
The Live Storage Company
T: 01295 709020
E: sales@live-storage.com
W: www.live-storage.com
Keith Wootton
Public Relations Consultant
T: 01327 830675
E: lsc@keithwootton.co.uk
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