| System Profile: Eastbay |
SIC: 5600 |
Hytrol chosen to move footwear & apparel for
Eastbay
Customer:
Eastbay
Wausau, Wisconsin
System Integrator:
HCM Systems, Inc.
Chicago, Illinois |
When Eastbay decided to double the size of the current facility to over
500,000 sq. ft. they requested direction and input from three qualified
system integrators. The current material handling system would require
complete redesign to handle to projected case rates of 60,000 orders per
day. It was determined that a series of tote handling conveyors and package
handling conveyors would be needed to fill the orders at the current and
projected rates. Eastbay chose HCM Systems, Inc. based in Chicago, Illinois,
to be the system integrator for the expansive complex systems solution.
The Hytrol ProSort 100 Shoe Sorter operates at 230
cases per minute and can handle 60,000 packages a day.
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Wave Picking:
Orders are generated from the current WMS system and printed overnight
to a paper pick ticket. The orders are placed in the pick racks for the
operators. Operators then pick orders to totes and place the completed
pick on one of two 300’ long live roller take away conveyors running
the width of the building. The two take away lines incline and merge into
a Hytrol high speed 2:1 roller merge.
Eastbay can pick up to 30 totes per minute for their multiple and single
orders that are generated by catalog and internet sales. It was the vision
of Eastbay to automate the Batch pick process that existed. The goal was
to reduce the wave time and increase the efficiency of the operators required
to "slot" the multiple orders. Required was a hardware and software
solution designed and installed to scan, track, and sort orders into "batch"
destinations. HCM completed this task using Hytrol’s high speed
pneumatic pusher design. The software solution allows Eastbay to greatly
reduce the time combining multiple items scheduled for a customer order.
All multiple orders are grouped and sorted using the "Batch"
sequence PC software solution.
Single Items:
Single items are picked to a color tote that allows the packers to determine
their required destination. Single items are defined as one item to one
customer. Single items are automatically conveyed directly to packing
and placed in a box or a bag and released to shipping. The packing operator
places the pre-generated tracking label on the case and places the item
on the outbound shipping line.
Shipping sorter:
HCM and Eastbay agreed that two Pro-Sort 100 sliding shoe sorters would
be required for the suggested layout and throughputs. The unique shape
and size of the product mix created challenges for HCM’s engineering
team. HCM and Hytrol developed Accumulating, Transportation, Merging and
Sorting equipment that would fit the specific needs of the products to
be handled. HCM developed and installed a PC mapping and releasing software
package that allows Eastbay to significantly reduce the labor hours required
during their peak production. HCM’s solution, installation and start
up provided for a significant increase in worker productivity. Installation
and commissioning were completed without impact on normal operations.
D.C. Director Pat Schmidt: "The
transition, the timing of the installation, the delivery of the product,
everything went smoothly without any glitches. I right now personally
would not use anyone else."
John Rapp (Assistant DC manager) "They gave
us exactly what we asked for." |
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| This is a vertical belt merge used to re-circulate
products from the main shipping shoe sorter when lanes are full. When
the infeed stops, the “swing belt” lowers. A slug release
directs products onto the lower line and re-feeds the sorter. |
Hytrol zero-pressure conveyors move products through
the system, holding them until the sorter is ready. This line can
store approximately 95 full totes. |
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