Dematic and Toll on track to deliver advanced logistics for adidas

23.05.2012

Third-party logistics (3PL) specialist Toll and logistics systems integrator Dematic are implementing one of the most sophisticated retail distribution systems in Australia for leading global sports and leisure brand adidas.

The new adidas national distribution centre (NDC), which will be operated by Toll Global Logistics – Customised Solutions, is currently under construction at Truganina in Melbourne, and is due to commence operations by October.

The NDC will include the first use in Australia of Dematic’s new RapidPick 1:1 ergonomic order picking stations, which deliver new levels of productivity, accuracy and safety in Goods-to-Person (GTP) order fulfilment.

Fast, safe, error-free picking with GTP

GTP delivers significant productivity, accuracy and safety gains compared to conventional order fulfilment. "By bringing the stock for orders to the picker, GTP eliminates the time spent by pickers travelling from order location to order location," said Dematic’s Industry Manager, Glenn Barnes.

"Automated handling of stock and orders not only enables operators to consistently and accurately pick goods at rates of 600 lines per hour, it also improves occupational health and safety (OH&S), presenting stock for picking at an ergonomic workstation.

"The associated reduction in forklift operations required for conventional order fulfilment also contributes to a safer workplace," added Mr Barnes.

The new Dematic RapidPick 1:1 workstations have just two positions to pick and put to – one for a tote with stock, and one for the order carton – making operation simple, quick and accurate. A height-adjustable display screen provides simple, clear data and graphics to indicate the product and quantity required for each order. Elevating work platforms ensure operators work at optimum comfort levels, improving OH&S and minimising fatigue.

Dematic’s warehouse control system (WCS) interfaces with Toll’s WMS, and has responsibility for co-ordinating all order picking activities, including replenishment and put-away, through to automated conveyor sortation for despatch.

Multishuttle storage, buffering and sequencing systems

Delivering stock to the workstations will be one of Australia’s first Dematic Multishuttle® automated storage, buffering and sequencing systems.

Unlike conventional ASRS, which typically use cranes to access stock, Multishuttle uses a fleet of self-propelled carts equipped with load handling devices (LHDs) to retrieve and put-away a range of storage media like totes and cartons, at very high speeds.

Incorporating 70 carts, the Dematic Multishuttle® has been designed to operate at around 2,000 dual cycle tote retrievals/put-aways per hour.

90m long, 14 levels high and with five aisles each double deep, the Multishuttle will initially provide capacity of 47,600 storage locations. It has been designed so that an additional aisle can be added at a later date, creating space for an additional 9,500 storage locations.
A standard Multishuttle cart services levels one to 12 of each aisle, with new Multishuttle Flex (MS-Flex) carts operating on the upper two levels of the system. Equipped with telescoping LHDs, MS-Flex shuttles can handle a variety of unit loads, such as, totes, trays and cartons of varying lengths and widths. Toll will put MS-Flex’s load handling versatility to good use, with the upper two levels being used to stage a variety of order types for shipment on specific dates to meet seasonal, promotional, and pack and hold requirements.

After being retrieved by a Multishuttle cart, product totes will be transported by conveyor to the RapidPick 1:1 workstations. At each of the workstations, cartons for orders will be delivered to the operator from a sequencing tower, capable of sequencing orders and stock totes for up to 40 orders at any one time.

Dematic’s integrated logistics solution for Toll also includes the fit-out of the NDC with narrow aisle ColbyRACK pallet racking, longspan shelving and custom racks for the storage of pallets, bulky goods and uglies, and the integration of RF for order fulfilment.
Toll Global Logistics – Customised Solutions National Design Manager, Arthur Dardoumbas, said: "During the project development phase, we worked closely with adidas in the UK, where they have been using Dematic GTP order picking as part of their order fulfilment strategy for several years. It was great to be able to take advantage of their knowledge and experience, and apply it to our own market," he said.

"Dematic’s global retail logistics experience and local track record for implementing and, importantly, supporting complex order fulfilment systems gave us the confidence to go ahead with one of the most technically sophisticated integrated logistics solutions Toll has commissioned in Australia," added Mr Dardoumbas.

"The new NDC will enhance Toll’s commitment to operational excellence and innovation in today’s competitive retail marketplace," he said.