Synergy Logistics invests in next generation picking

Synergy Logistics has secured funding from the UK’s innovation agency, Innovate UK, to develop the next generation of its Snapfulfil WMS.

With a working title of ‘Choreo’ (from ‘to choreograph’), the aim of the project is to allow Snapfulfil to deliver robotic levels of efficiency without the high levels of capital expenditure and fixed capacity associated with traditional warehouse automation technologies.

Managing director Tony Dobson explains: “We originally won a grant several years ago, £250,000, which we matched. This allowed us to improve pick rates with a Pick-to-Light trolley using modular kit rather than having it fixed to the trolley. 

“The second grant will help us develop our very complex algorithms which guide the picking trolleys, or other picking vehicles, around the warehouse as efficiently as possible. This puts the onus on moving vehicles, rather than people, a goods-to-man system that we believe will create efficiencies.”

Using a network of sensors to supply accurate, real-time 3D locations of both pickers/trolleys and stock in the warehouse, the next generation system will include routing and scheduling algorithms to dynamically optimise the location and movement of people and goods within the warehouse, allowing these to be altered in real-time in line with both planned and unplanned events.

Tony adds: “The key to the algorithm is assessing the order pool, assessing the locations products are in, assessing the availability of staff, and melding this data together to inform the most efficient orders to pick into totes.”

Building on its existing Snapfulfil WMS, Synergy’s latest project has been conceived to allow small and medium-sized eCommerce retailers to compete with much larger retailers. The solution is said to offer the benefits of a goods to man system, without the need for expensive automated plant and equipment.

Innovate UK will contribute in the region of £240,000 towards the total cost of the project.

“The system leads to eye-catching benefits. It cuts labour in half, reducing walking time, increasing accuracy, and reducing training time,” says Tony.

“For eCommerce clients, they tend to have efficient picking but they are also concerned with customer satisfaction and returns.

“What we’re doing here is taking very high accuracy up to extremely high accuracy.”

The development is a response to increasingly complex warehouses.

“Some orders involve multiple line items and we want to solve that problem, while also allowing the warehouse to have the flexibility to simultaneously manage the picking of 100 single-line orders into one tote – and then decanting at a pack station,” adds Tony.

“Everything within the WMS is configurable, so it can adapt to different order profiles, different warehouse needs, we have probably the most powerful configuration engine in the industry.

“We have also invested in a more sophisticated packing facility using omni-scanners, like a supermarket check-out, to scan items through. If required this introduces a double scan so the error rate we’re getting is negligible. Remember, the picker (using Pick-to-Light) has already scanned the location or the product to identify they’ve picked the right product.

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“The unique thing is the algorithm, which we didn’t have before. A multi-dimensional algorithm is complex and it took time to develop, it took a lot of testing to get to the level of a human (albeit with a person taking 10 times longer to work it out).”

The company’s ambitions to further develop cutting edge picking solutions is matched by its investment in growth.

Synergy Logistics has made a major investment in a headquarters in Castle Donington (near Marks & Spencer’s million sq ft e-commerce distribution centre), complete with a 30,000 sq ft warehouse.

The multi-use warehouse features a demonstration area where companies can view a variety of picking configurations before they decide which approach will best suit themselves.

The live test and training environment will be used to show off the Snapfulfil WMS, along with a range of other innovative warehouse solutions.

The company’s 60 strong UK team will re-locate from Synergy’s existing head office in nearby Loughborough early this year.