Case Study:
Throughput Jumps with
New Conveyors
Customer
BuySeasons
The Internet Specialty Retailer
Systems Integrator
Babush Material Handling Systems, Inc.
Sussex, WI
A Company on the Move
BuySeasons is a fast growing online costume retailer with over
10,000 items available to choose from. When they decided a
jump in productivity was desperately needed, they looked to
Babush Material Handling Systems, Inc. to install a conveyor system
that would provide them with the ability to handle seasonal
increases in orders that are consistent in their industry. The
main objective was to reduce the time from order picking to
shipping to insure delivery of costumes in the timeliest
manner. With three main seasons - Halloween, Christmas,
and Easter, it was imperative that the system had the ability to
handle the peck loads that occur as the special dates gets
closer.
"This operation is helping BuySeasons
meet its strict service commitment to customers.
We are extremely impressed with the expertise Babush offered;
they were able to take our vision and goals and turn them into
reality."
--President and CEO Jalem
Getz
How the system works:
The order pickers take carts along rows of racks and pull items
to fill each individual order. These carts are then taken to 20
packing stations where packers place the items and the packing
slip in boxes that best suit the size of the order. The filled
boxes are placed onto the live roller accumulation conveyor
running in front of each packing station. The boxes then travel
to a Live Roller Zero Pressure Accumulation Conveyor which
controls the boxes before they enter the divert area before the
shipping stations. Through the use of a Double Powered Pivot
Diverter they are able to function with maximum efficiency based
on their order volume. BuySeasons can run one lane in the
shipping area when volume levels are low, requiring only one
shipper to handle the load. As the volume increases they are
able to activate the diverter which allows them to divert boxes
to two separate lanes and increase the amount of shipping
personnel to four at peck volume levels. After the boxes have
been scanned and the shipping label applied the boxes move down
the conveyor to the box sealers. Here the boxes are
automatically closed and taped, then travel to a merge area
where two lanes converge and the boxes travel single file to the
loading dock.
Benefits
The previous system was a basic roller coaster design utilizing
gravity conveyors. This system was able to handle 8000 boxes
over 3 shifts at peck volume. The new system has the ability to
handle 20,000 boxes over a 2 shift period. Babush designed a
system that provided BuySeasons a 100% increase in throughput
with a 25%-35% increase in productivity; therefore requiring
less labor during non-peck volume levels. An additional benefit
was BuySeason's ability to reduce costs related to packing
errors resulting in less returned items.
System Hy-Lites
- Facility Size: 81,000 sq. ft. - 66,000 sq. ft. of
distribution
- Employees: 55 full time employees, seasonal peck of 250
employees
- Product Handled: Online costume retailer
- Types of Conveyors: Minimum Pressure Accumulation Live
Roller Conveyors, Live Roller Curve Conveyors, Zero
Pressure Accumulation Live Roller Conveyors, Live Roller
Spur Conveyor, Double Powered Pivot Diverter, Flexible
Roller Conveyor
Bevco / Babush
Introduces New General Manager
It is our pleasure to introduce Marc Jorgensen, recently
appointed General Manager of Bevco Engineering / Babush Material Handling Systems, Inc., a systems solutions provider of
industrial controls and integrated material handling
systems. Jorgensen is responsible for managing and
integrating the engineering, production, financial and human
resource functions of our organization. Previous to
joining the company, Jorgensen was president of Jorgensen
Conveyors for 10 years, successfully leading that organization
in the development of a formalized quality assurance system,
lean manufacturing and establishment of a culture of
continuous improvement. Jorgensen has a technical background
in accounting and a CPA credential. Jorgensen holds an MBA
from the University Wisconsin-Milwaukee and a Bachelor Degree
in Accounting from Miami University in Oxford, Ohio.
"I am excited about the opportunity that Bevco/Babush
has given me as its General Manager. I look forward to helping
build on the company's successful past and help cultivate an
environment of continuous improvement. Bevco/Babush has
established an impressive customer base through the company's
focus on customer satisfaction and loyalty; I will seek to
assist in supporting those strong partnerships with our
customers."
Welcome Marc! We at Bevco Engineering and Babush Material Handling Systems, Inc. look forward to the opportunity to serve
under your leadership.
Quick Tip of the Month
Using Zero Pressure conveyors in assembly
and inspection applications
  When
using zero pressure conveyors in assembly and inspection
applications, it is often necessary to remove a product from a
conveyor for a short time and then replace it. It may be
desirable to keep the "inspection" zone empty and to
hold back any incoming product until the removed product is
replaced. An easy way to do this is to provide a zone stop
signal to the inspection zone and to use the "zone on
delay timer" function of EZLogic. This timer may be set to
hold back any incoming product for 15, 30, or 45 seconds. The
inspection zone will remain empty and stopped during this time.
When the product is replaced in the inspection zone, the zone
stop is released to allow the boxes to advance normally.
Did You Know...
Our palletizers offer slow-speed economical line solution.
The FL10 floor level palletizer provides an optimal
price/speed combination for smaller production operations. For
an economical price this automated palletizing solution stacks
product at more than 10 cases per minute (CPM).
Small enough to be installed through 8′ x 8′
doorways, the FL10's compact footprint utilizes less than 60
square feet of floor space, often a critical consideration for
smaller plants. It comes preprogrammed with easy-to-run common
palletizing patterns for simplified operation. The FL10 also
features a welded-frame and rugged construction to assure
long-lasting operation and reliability.
Call Today for your Free Systems
Analysis!
262-820-2500
Product Spotlight
 Hytrol's
Zipper is a wide belt conveyor fitted with fixed belt
plows for the purpose of merging cartons from multiple parallel
lines. The conveyor utilizes a unique belt type designed for
tracking on a low length-to-width ratio. Also, tracking idlers
are angled and skewed to properly position the belt on the
pulleys.
The plow structure is floor supported and spans the conveyor
width. This structure is used to support the belt plows over the
conveyor belt and near the belt for low profile cartons. The
plow support is designed to allow adjustment of exact plow
location.
The conveyor and plows are direct driven with shaft mounted
gearmotors and variable speed drives.
FEATURES
- High Speed Capability
- Variable Speed Drives
- Belt Designed for Ease of Tracking
- Adjustable Positioning of Plows
- Powered Belt Plows
About Us
Babush Material Handling Systems, Inc.
provides state of the art material handling services through
rapid development of new technologies and partnering programs.
With over 75 years in material handling integration, Babush is
positioned to provide you with the most cost effective
solutions, on time deliveries, and high quality customer care
for all of your material handling integration needs. Some of our
services include: Audits & Consulting, Layout &
Simulation, Project Management, Turnkey Installation,
Maintenance & Services, and more. Visit our website for more information
and to find out how Babush Material Handling Systems, Inc. can become
your Single Source Solutions Provider!
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