Automated solution promises non-stop logistics

There is clear demand for faster eCommerce automated fulfillment solutions, however, the search for new solutions is quite difficult as the design basics are hard to define in such a dynamic environment. This is a huge challenge on the supplier and the operator side – and it can only be resolved with new concepts.

The wheel does not always need to be reinvented, and groundbreaking innovations can arise from a solid ground of standard modules that have been proven in practice already. This is how Witron has created its eCommerce solution named OFS.

High cost-efficiency even with a small-volume picking operation, error-free picking directly into the dispatch carton, efficient order consolidation, shortest throughput times, and a transparent and integrated returns management, the OFS fulfills all these requirements. Moreover, the OFS also supports start-up enterprises in the online trade due to its modular design and its flexibility across all stages of a business cycle.

In this compact and clearly structured eCommerce solution, the Witron OPS system (Order Picking System) acts as logistical core element that is able to efficiently manage small, middle, and very broad article ranges. The articles are stored in totes of different sizes – often divided into several sub-sections. It is possible to stack several load carriers above one another on an AS/RS location in a space-saving manner. Highly dynamic mechanical elements as well as small, light, and high-speed stacker cranes allow the shortest possible throughput times with the focus on same-day- or next-day-delivery. Multi-functional workstations ensure maximum flexibility and the fulfillment of individual customer demands for both, a 1:1 order picking and a parallel picking of several customer orders directly into the shipping carton. Integrated packaging lines and a warehouse management system equipped with a large number of eCommerce functionalities including features for volume calculation and order consolidation optimise the delivery process in a sustainable manner. 

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A great challenge for the eCommerce trade is and will remain the returns handling. This primary task is solved by Witron’s DPS system (Dynamic Picking System). In terms of efficiency and cost-effectiveness, the DPS has been setting standards throughout the logistics world for many years and is the ideal solution for the returns process based on its flexible use. 

All incoming returns are transported via the conveyor system to the quality control stations and to pre-defined repack workstations. Damaged products will be either returned to the supplier or disposed. Undamaged items will be repacked into storage totes and stored into the returns warehouse using stacker cranes. These storage totes are divided into several sections to allow the parallel repacking of different articles into one storage tote, as a return often consists of only one item. To ensure a maximum safety and transparency for the employee, the repacking process is visualised by a pick-by-light system. The returned goods will then be consolidated with similar stock items just as done in a “classic” DPS picking process, before the consolidated storage tote is returned to the OPS eCommerce process. Flow channels or buffer areas allow a flexible handling of returned goods that currently cannot be repacked or only partially repacked. Stacker cranes are used for a flexible provision of the totes that need to be consolidated at the workstations. 

The overall concept also considers large-volume and non-toteable articles. These will be repacked into layer-trays after receiving and thus allow a static and dynamic provision of several different articles in a pallet flow rack – supply is done via stacker cranes. This saves space and driving distances for the forklift driver, and increases the article variety in the pick front. The use of a pallet rack on a forklift allows the parallel picking of several different customer orders into the dispatch carton. The picker is supported by a pick-by-voice system. Witron’s IT ensures an order consolidation of all orders that were picked in the OPS area – and therefore a guarantee that customers only receive one dispatch carton. 

Witron shows with the OFS solution that many benefits can be generated for the customer also for new and future market requirements based on practically proven solutions – true to the motto Innovation through tradition.