Kiddicare Prepares for Multichannel Success
SSI Schaefer has just completed a second major project for baby specialist, Kiddicare.
SSI Schaefer worked with Kiddicare, now owned by Morrisons, in 2008 to install a pallet racking bulk store area and multi-level picking module with an integrated conveyor system into its then 160,000 sq ft warehouse in Peterborough – also home to Kiddicare’s flagship super store.
Following the brief to extend this system in December 2011, it took SSI Schaefer just seven months to finish the installation and provide Kiddicare with thousands of additional pallet positions and pickfaces for both cartons and small items, increasing the size of the warehouse footprint by 3180 m².
Kiddicare Logistics Manager, Steve Poulter, said, “SSI Schaefer has helped Kiddicare hit our expansion targets to support our rapidly growing multichannel business operation. The teams involved work effectively together to deliver the project on time and in budget.” The Kiddicare warehouse, which stores a significantly high value of stock ready for despatch, currently supports a predominantly online business; however there are plans to open ten additional retail outlets across the UK, the first opening this Autumn. These stores will be replenished with goods from a new central distribution centre in Daventry.
Now comprising wide aisle, double-deep adjustable pallet racking, a substantial area of the original racking was removed, relocated and reassembled to accommodate a new three-tier rack-supported pick tower linked to the existing pick tower by high level bridge walkways to enable operator movement between the two areas.
The top floor of the three-tier pick tower consists of shelving dedicated to the storage of small items; pallets are stored below, on the ground and on the two remaining levels. Mesh decking is installed above the pallet locations on these two levels to provide additional carton storage.
A separate conveyor system now takes complete and partly-picked orders in totes away from the small items picking area before merging with the existing conveyor system, routed via existing picking zones, to arrive in the packing area. A new heavy duty spiral chute to enable fast track distribution around the warehouse was also installed.
SSI Schaefer subcontracted the in-rack sprinkler system to Tyco Fire & Integrated solutions, the electrical installation and data cabling was outsourced to EDI Services Ltd.
To minimise disruption to daily operations, SSI Schaefer meticulously planned the project to ensure Kiddicare remained fully operational throughout the entire period of installation.
A smooth transition for Yankee Candle® Europe
The world’s best loved candle and largest manufacturer of scented candles extends its state of the art picking system to increase distribution capacity following the move to the new European Headquarters in Avonmouth.
Yankee Candle® Europe relocated its new premises in June 2012 to accommodate its plan for future growth of the business. The increased warehouse facilities enables higher levels of stock to be held onsite, increased volume of orders to be dispatched for retail outlets, export customers and a growing online business. The move also enables the company to avoid the additional cost of off-site storage.
Having installed the original highly customised ‘flexible zone’ pick-to-light system in the previous building, to improve picking efficiency and reduce picking errors, SSI Schaefer were contracted back to extend the system to accommodate the new warehouse and increased distribution at the new site.
In just one month, SSI Schaefer dismantled the existing zone picking system made up of carton live storage, pick-by-light picking and conveyor-based carton sortation, transported it to the new DC and reinstalled it in conjunction with a complete reconfiguration and extension. At 175,000 square feet, this new DC is almost three times the size of the original facility and the addition extra pallet positions has significantly increased storage capacity.
There are now more picking locations in the carton live storage, an additional full case ‘pick to belt conveyor’, additional ‘sort-to-route’ sortation lanes for completed orders and separate shipping carton feeds from two zone picking areas. The whole system has also been given a complete software overhaul including additional interfaces to contract carriers’ systems.
Bruce Mitchell, Operations Manager, Yankee Candle® Europe, said: “SSI Schaefer ensured the movement of the picking system to our new DC in Avonmouth was accomplished without a hitch.
“The additional full case picking functionality provided by the extended system has considerably speeded up our operation, enabling us to more tightly control our picking and wave management. We now have a system which is future-proof and flexible enough to accommodate further expansion when needed.”
The extended automated system which includes additional sortation capability and a new automated full case picking area has and will enable Yankee Candle® Europe to continue increasing its throughput efficiency of the picking operation and accommodate with ease, future requirements of its growing internet business.
