Working smarter, not harder
Workwear specialist Portwest futureproofs its business with major investment in automation.
PORTWEST, THE world’s fastest growing online workwear company, has successfully commissioned a new, fully automated storage and retrieval system (AS/RS) at its distribution centre in Barnsley UK. Designed and installed by Japanese automation specialist, Daifuku, the system replaces what was formally a fully manual fulfilment process, transforming the business’s ability to satisfy demand for its products.
Following the implementation of Daifuku’s four-crane AS/RS system, Portwest has increased its productivity levels tenfold. Glynn Clyde, global warehouse and logistics executive at Portwest explained: “Prior to our adoption of automation, our fulfilment process was entirely manual. In practice, this meant that we were able to complete no more than 30 boxes an hour. With our new automation system, we can now fulfil 300 picked boxes per hour.”
Fully operational by late summer 2024, the new warehouse automation system at Portwest’s 15,000 sq m facility has significantly reduced mis-picks and more than doubled handling capacity, thereby enabling the business to meet anticipated demand for its products, which include high viz jackets, PPE kits and safety gloves.
Automated high bay storage
Daifuku’s AS/RS comprises four high bay aisles serviced by four automated twin-fork Mini-Load cranes. High-density racking creates more than 76,000 unique locations within the upgraded facility. At more than 130 metres in length, the racking installation at Portwest is believed to be one of the longest installations of its kind in the UK.
Key features of the system are its double-deep design and the ability of the cranes to transport two cases simultaneously. This enables greater storage capacity while providing high throughput, allowing greater warehouse efficiencies to be achieved.
Technology in operation
The Portwest operation is fed by central supply of cartons, which are transported to appropriate zones (A, B or C) of the high-bay storage racking, depending on their demand profile. Daifuku worked closely with ULMA, its preferred European partner, to develop and install the in-feed transit conveyor systems.
With nearly 60 years’ experience and over 35,000 stackers cranes installed, Daifuku’s AS/RSs are globally respected for their reliability and quality. Furthermore, with updates and developments over the years, the cranes have been made lighter and employ smaller motors, reducing electricity consumption.
Russell Hutchinson, Daifuku UK sales manager, said: “One of the benefits of this system is its simplicity. Once a consignment of goods arrives, all operators need to do is enter a carton into the system and automation will do the rest. If it has a barcode or label, our automated storage system will store it away until it is called upon.”
Automation for the nation
Portwest’s experience demonstrates that appropriate technology within the intralogistics function can transform the efficiency of manual handling processes.
