Upgrade of existing zone picking system for DA Retail including 4.500 pick-to-light displays
DA Retail Groep is a leading drug stores chain in the Netherlands. The company centralised its distribution operation in Zwolle, the Netherlands. To accomodate a higher workload, the existing order picking system was expanded and upgraded. This was done during normal operations, without disrupting service to stores.
The existing warehouse control system (WCS) was replaced by Vanderlande Industries' VISION.ZPS which enhanced throughput by balancing the workload across the zones, maximising efficiency in the zone picking system. It also made new features available such as order picking supported by Pick-to-Light and RF- terminals. VISION.ZPS interfaces with DA Retail's host system. The VISION Supervisor Cockpit helps the supervisor to detect potential bottlenecks in the process early, so they can be eliminated before the order flow is affected.
The complete PLC controls of the existing conveyor system were replaced to bring them up to current industry standards and ensure spare parts availability for many years to come. The zone picking system was upgraded and expanded. It now consists of 28 zones, an automatic tote destacker and an automatic tote labelling system. Fast-moving products are picked from flow racks supported by Pick-to-Light displays (over 4.500 units). This enables operators to achieve very high pick rates and high pick accuracy. Slow moving products are picked from shelves supported by RF terminals. During busy periods multiple operators can pick independently in a single zone by working on different order totes. The advantages of the new system include higher productivity, short order processing times, and high pick accuracy.