Freight Forwarding

Key Highlights 

The Element Logic Solution for Toll Group 
CONSULTANCY APPROACH: As part of Element Logic’s consultancy approach, we analyzed the issues and limitations that needed to be addressed. Toll Group found themselves in a situation where, after landing new accounts, they could not pick fast enough to meet expectations. 

AUTOMATED SOLUTION: Implemented a Put Wall system, transport conveyors, along with the software to interface with Toll Group’s WMS. 

ENHANCED OPERATION: The solution has increased speed, accuracy, space efficiency and increased the number of UPH. 

THE CHALLENGE 

Toll Group’s new account added 13,000 SKUs to their system, making it an arduous task to pick, at most, 20,000 units per day. In addition to this, Toll Group was on a short deadline and needed to meet a tight schedule, while constrained by a limited budget. 

THE SOLUTION 

After evaluating Toll Group’s business needs and budget, the best solution was to implement a Put Wall that would allow them to process 60,000 units per day. “We had another proposal by one of your competitors and they had a 26-week lead time,” David Hendrickson, Logistics Solutions Engineer, said. “But Element Logic knocked it out in about 13.” 

“The system is doing exactly what it’s supposed to,” Hendrickson said. “We can’t feed the beast fast enough.” 

THE SYSTEM 

Element Logic provided Toll Group with a Put Wall where each wall can handle a total of 40 orders fulfilling both retail and e-commerce.  

“On e-commerce we’ll run waves on orders of one, pick that in bulk and pack it,” Hendrickson added.  

A picker is assigned to an aisle and through it, picking everything the system tells them from the right and left. As the picker moves along, there’s another picker right behind them. If they pick at maximum, they pick six totes, and when the aisle ends, they drop their totes off by the wall.” 

They then go over the staging area to make sure all the orders are 100% complete, they put them on a conveyor and drops them off at the Put Wall area, where it’s automatically diverted to the right place. The operator scans the complete orders and they’re inducted into the wall where the lights lit up. Orders are packed, and when they’re done with the tote, they simply push it onto the belt. 
 

“The system is doing exactly what it’s supposed to,” Hendrickson said. “We can’t feed the beast fast enough.” 

ABOUT TOLL GROUP 

Toll Group, part of Japan Post, is a transportation and logistics company with operations in road, rail, sea, air and warehousing. Toll operates a network of 1,200 sites across 50 countries, with an Asia Pacific focus. 

The post Toll Group Case Study appeared first on Element Logic US.

With the help of Element Logic, wholesale retailer New Wave moved into a new warehouse without the customers noticing, in the same period picking up a Supplier of the Year award.

New Wave is a Norwegian textile wholesale retailer, specializing in sportswear and workwear. With a stable growth and high seasonal peaks, they acknowledged that their old warehouse was no longer doing the job.

“It was too small and could not keep up with customer demand. It was simply not efficient for us anymore,” says Morten Halvorsen, CEO of New Wave. “We knew we had to take a step into the future and automate our warehouse.”

Today, New Wave has moved into a brand-new warehouse in Østfold county. During the two years of preparing the move, Element Logic has been there every step of the way, securing a smooth transition as well as optimizing every inch of the 8 000 square meter building.

Up and running from day one

“We have worked closely with New Wave throughout the entire moving process. This enabled New Wave to acquire ownership of the technology, and us to gain valuable insight on how the system could be optimized,” says Kjell Blakseth, consultant at Element Logic.

“They have delivered all the warehouse equipment and worked together with our construction contractor for optimal warehouse performance. Everything has been delivered on time and successfully set up. We were up and running from day one,” Halvorsen continues.

With the automated AutoStore solution from Element Logic, the picking capacity has increased by 300 percent and the picking area has been reduced with 8000 m³.

“This result is just from the few months we have been here. Now that we are approaching a peak season, we will really get to see the automated warehouse in its full capacity,” says Halvorsen.

He is looking forward to the opportunities of scalability in the future.

“Our estimates show that we can double our revenue in this warehouse without having to expand the warehouse further.”

Motivated warehouse workers

Another positive consequence after moving from the old to the new warehouse, is the effect on the workforce. The implementation of AutoStore has reduced the number of forklifts by half

“An ergonomically adapted workday, with cleaner air and modern technology has had great impact on the employees,” Halvorsen explains.

Controller and warehouse worker Martin Nordahl in New Wave confirms this.

“Your body is no longer sore when you wake up in the morning, and in general I think the atmosphere in the warehouse has improved significantly. In designated warehouse zones you can now work while listening to music or podcasts, because you don’t have to worry about being run over by forklifts,”Nordahl states.

All in all, New Wave has become a much more agile and efficient company after automating their warehouse.

“In the future, we expect a healthier business with increased customer satisfaction, based on quicker deliveries with less mistakes. Simply put, we are becoming a better supplier with the help of Element Logic and AutoStore,” the CEO of New Wave concludes.

The post Productivity up 300 percent for New Wave appeared first on Element Logic US.