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Conveyor Applications
Conveyors Provide Solution to Order-Processing Challenge Conveyorized distribution center handles current needs while positioning Starlight International to reach aggressive growth projections.
Starlight International is a fascinating success story. It was founded in 1993 by Steven Goldberg, a well-known Hollywood producer (credits include "Fun House," America's top rated show for kids) and music tour promoter. The company originally began as a manufacturer and marketer of weight-loss products. Since then, the product line has grown extensively and now includes general nutrition, energy, and health and beauty products for men and women. 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 company's old distribution center was a case in point. The crowded 10,000 square-foot facility simply could not keep up with the volume of orders pouring in. Line space was insufficient for the growing number of SKUs processed. Space constraints dictated that serpentine pick lines be configured just to get the orders to the manifest station. In short, the old facility was a labor-intensive, cumbersome operation that was not delivering the kind of productivity needed to efficiently serve the customers-Starlight International's independent distributors who sell the products to consumers nationwide. All that has changed with the new distribution center. The Monterey operation represents a collaborative effort between Starlight International and FloStor Engineering, a Hytrol distributor and systems integrator based in Hayward, California. "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." The new installation features the latest in computer controls and an integrated network of conveyors from Hytrol Conveyor Co. A Streamlined Flow
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 (a 24-inch zero-pressure accumulation conveyor ABEZ model). This leads to another powered takeaway conveyor that transports the orders to the pack out/manifest stations. Orders that need additional items remain on the picking lines and proceed to the subsequent zones until completed. A powered SP conveyor transports the totes between the main picking cells, effectively eliminating any manual movement or handling. When the order is complete, the tote is moved onto the center powered conveyor in each main cell, which links up with the main line conveyor leading to the pack out station. 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 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. A planned Warehouse Management System (WMS) will only further increase productivity. Enhancements to the computer controls soon will be coming on line, too. Starlight International says that its guiding philosophy from the beginning has been to do things right, not half way. The Monterey distribution center is an outstanding example of that philosophy at work. Monterey Distribution Center At Starlight International, the order-fulfillment process begins at the express lane of the initial picking cell. An operator takes an empty tote off the upper conveyor line and begins filling the order. As orders are completed, they are placed on the center powered conveyors, which moves them directly to the main takeaway conveyor. Orders that require additional items remain on the pick lines and proceed to the successive picking areas. The completed orders are automatically ship verified at the pack out stations in preparation for delivery by UPS, Federal Express, or USPS.
Details on the Installation
Company: Starlight International
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Starlight International had two overriding objectives for its new
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-facility that recently opened in Monterey,
California.
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 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 now 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, a live-roller SPEZ model, for transport back to the first
picking cell. There the order-fulfillment process starts all over again.
