OverviewA distribution center for a home furnishing chain struggling with the fulfillment of online orders from over 10,000 skus.

The company faced major challenges with order processing efficiency and speed that was needed to fulfill and consolidate increasing orders for same and next day deliveries.

With the benefit of robotic “Butlers”, goods stored in flexible mobile racks are automatically delivered to various picking stations, thereby eliminating walking for the associatesChallengeTotal volume of orders was increasing while lines per order decreasing due to changing online customer demands, causing delay in order processing More customers were expecting same and next day delivery putting pressure on their existing manual and rigid automation systems to handleNew SKUS frequently added into inventory as well the need to accommodate seasonal goods for extended periods of time required extensive planning Existing systems were rigid and inflexibleResolutionThe GreyOrange Butler robotics delivery system accelerated order processing by delivering goods to directly to operator pick stations, all queued up in proper sequence Using artificial intelligence the Butler system places racks of goods with the more popular items closer to the pick stations, increasing overall efficiencyIn real time, the Butlers use continuous ABC analysis to optimize where racks should be positioned within the warehouse, which is helpful for seasonal items.

New system highly flexible, modular, and scalable.

OverviewA third-generation family owned electrical parts supplier in the Los Angeles area was challenged with growing product demand and increased business opportunities due to manual processes that limited capacity as well as congested floor space limiting the growth of new SKU mix.ResolutionTo help overcome these and other challenges, McCombs-Wall was selected to lead the design and implementation of a semi-automated materials handling solution for the new facility.

A new storage / fulfillment system interfaced with ORACLE allowed the customer to add desperately needed SKUs along with a tremendous increase in order picking capacity.

System enhancements included a new two story seismically designed pick module for split case and full case picking which included a powered spiral.

To manage specialty SKUs a 22-foothigh vertical storage carousel (Lean Lift) was also provided.The conveyor system was designed to automatically deliver empty corrugated cartons within the Pick Module to designated pick zones.

If additional picks are required, the system delivers them to the next picking zone until the order is complete.

Cartons are then conveyed to a check weighing system and finally sorted to the appropriate shipment lane.

Various kinds of software are used to track the material handling system’s working and activities involved in the whole supply chain management cycle.

All this including logistics planning and execution, order management, etc.

with sophisticated setup software that not only helps to reduce the workload but ensure the next-level productivity and overall efficacy.Although there are tons of various sorts of software used accordingly as per need in the material handling industry but some of the most widely used and essential ones are the following:Warehouse Control Systems (WCS)Warehouse Management Systems (WMS)Workforce Performance Management Systems (WPMS)Transportation Management SystemsSupply Chain Visibility SystemsForecasting and Order Management SystemsYard Management SystemsAutomatic Identification and Data Capture SystemsAll of the above-mentioned types do follow the basic principles of material handling systems.

We will now discuss the specific role and functionality of every sort of software and will try to understand their working too.Warehouse control systems are the kind of material handling software that is essentially used to gain control over the hybrid and fully automated machines operated under the supply chain cycle, performing a variety of different tasks.

They are responsible for dealing with small low-level simple machines along with high-level robotic apparatuses as well.Warehouse management systems are the kind of material handling software that is meant to control and monitor the working of humans operating the machines, participants as laborers or workers, dealing with time management, calculations regarding attendance of employees, etc.

These particular kinds of software are specialized for calculations, record keeping, data storing, and data management of all types.Workforce performance management software keenly focuses on achieving the set parameters and performance goals in the material handling system environment.

OverviewA national parts division of one of the top automotive OEMs was bursting at the seams with annual SKU growth, limited space, and a confluence of machines interrupting the safety of various work processes.

McCombs Wall collaborated with the client to provide a winning solution capable of being implemented in several phases due to the difficulty of deploying in a live operating environment.ResolutionThis modernization effort incorporated several facets which included the decommissioning and de-installation of existing infrastructure (racking systems, modular offices, multi-level pick modules, conveyor,packaging systems and obsolete automation, etc), the integration of new automation technologies (conveying, palletizing, vertical lifts,sorting, packing, picking, `put’) and up-to-date storage solutions (racking, picking systems, case flow, etc) into a more efficient, safe, and productive facility operation, interfaced to ORACLE.In addition to the above, MWI was selected by demonstrating our ability to manage the difficult and tedious aspects of the project in multiple phases — for which various seismic calcs, fire sprinkler, and lighting requirements were included in all of the permitting efforts managed by MWI.