The Sortation Palooza - MWPVL€¦ · Circulation Sortation Cross-belt sorter Tilt tray sorter...

The Sortation Palooza

Track T5 Session #1

| 2 0 1 4 M A T E R I A L H A N D L I N G & L O G I S T I C S C O N F E R E N C E S P O N S O R E D B Y D E M A T I C | W W W . M H L C . C O M | 2

Marc Wulfraat

▪ www.mwpvl.com

▪ 514-482-3572 x 100

▪ [email protected]

▪ Dematic

▪ President

Bob Kregel

▪ V.P. Global Product Management

▪ MWPVL International

▪ [email protected]

▪ (262) 860-6503

▪ www.dematic.us

mailto:[email protected]

mailto:[email protected]

| 2 0 1 4 M A T E R I A L H A N D L I N G & L O G I S T I C S C O N F E R E N C E S P O N S O R E D B Y D E M A T I C | W W W . M H L C . C O M |

Abstract

3

Sortation systems have been acknowledged as "the heart of the

modern distribution center."

Fueled by the impatience of ecommerce customers, the eruption of

SKUs and the intertwined network resulting from omnichannel,

sorting goods inside the DC has gone from complex to perplexing.

In this comprehensive review, our sortation scholars will present a

multitude of contemporary sortation solutions in terms of function,

specifications and application. A deliverable from this class will be

a clear selection matrix to aid you in making design decisions that

you won't regret.


Agenda

4

What is a sortation system and when is it needed?

What are the basic components of a sortation system?

What types of sortation systems are available?

What options exist?

What considerations are important when choosing a

sortation system?

Questions & Discussion


Sortation Definition

5

Sortation is a process that orders items according to

specified criteria

It can serve as the heart

of an efficient

distribution center


Sortation System Definition

6

Sortation can be a manual process, a semi-automated

process, or a fully-automated process

A sortation system identifies products and/or

packages (i.e. entities) and in turn transports, merges,

inducts, separates, sorts, routes and/or consolidates

these entities to specified destinations as per the

requirements of the distribution operation

Sortation


When Do We Need Sortation Systems?

7

Sortation systems are typically deployed when

a distribution center has one or more of the

following characteristics:

- Batch picking: Multiple orders are grouped together and picked as a

single parent order to reduce travel time and afterwards the child

orders need to be sorted

- Multiple pick areas and/or material handling technologies are

picked independently and in parallel; and need to be merged prior

to packing

- Goods need to be moved between different areas, floors and

buildings

- Completed orders need to be sequenced prior to loading (e.g. by

carrier, by weight, by load/stop)

- Flow through distribution such as in the Retail Industry


The Main Benefits of Sortation

8

Sortation systems allow companies to increase

throughput in a distribution center because

picking processes can be in parallel instead of

in serial

The enabler for high speed batch picking and

flow through operations which remove

significant labor cost from a DC operation

Highest levels of shipment accuracy can be

achieved


Sortation System Design Considerations

9

Decision Criteria Design Data Requirements

Throughput Volume Requirements

& Speed

• Average and peak of sorts per minute

• Average and peak diverts per minute through

each destination point

Packaging format, size, shape,

diversity, and conveyability of

packages

• Type of packaging material, fragility, weight

distribution, flatness of entity

• Product orientation

• Product mix

Unit Load Characteristics • Length, width, height, weight of entity being

sorted

Operating Environment • Temperature, dust, oil, obstructions

Physical Site Constraints • Columns, clear height, doors

Accumulation & Recirculation

Requirements

• Buffer requirement leading up to sortation

• Recirculation after sortation discharge

Financial • System cost and ROI

Other Considerations • Ergonomics, noise, energy requirement,

maintenance, equipment interfaces

• Bar code label size, location & symbology


Different Types of Sortation Systems

10

Sortation Type Available Technologies

Manual Put Wall / With Lights

Conveyor Systems Right angle transfer with bands or rollers

Conveyor with swing arm, pusher or deflector

Strip-Belt Sorter

Positive Belt Sorter

Swivel wheel sorter or pop-up wheel sorter

Linear Sortation Sliding Shoe with Angle Divert

Sliding Shoe with Parallel Divert

Sliding Shoe with Bi-Directional Divert

Circulation Sortation Cross-belt sorter

Tilt tray sorter

Bomb-bay sorter (1-tray, 2-tray, quad-tray)

Automation Shuttle system

Please note that there are other types of specialty and hybrid sortation systems not listed here that are excluded

due to time limitations for this presentation.


Sortation System Component Diagram

11

Merge

Facilitates

Flow of Unit

Loads

Induction

Minimizes gaps

between loads and

maximizes the flow

onto the sorter

Sorter

Diverts items

to one or two

sides

Take-Away

Moves items

away from

the sorter

Controls

Tracks items

and ensures

accurate

flow


Sortation System Components in Detail

12

Subsystem Options Description

Merge • Merge Options

- Single

- Dual

- Sawtooth

- Multilane

• Receives products/cartons from

various sources or areas

• Controls / regulates / funnels /

singulates the flow of cartons into a

single stream prior to sortation

Induction • Gap Options

- Brake belt or meter belt

- Blow through

- High rate gapping unit

• Gateway to sortation system

• Identifies carton and destination

• Gaps and spaces cartons to

optimize sortation system

Sortation • Tracking Options

- Relays, Programmable logic

controllers (PLC), Computers

- Diverter Options

- Manual, plow, pusher, pop-

up, slat-shoe, tilt- tray, etc.

• Tracks carton through to

downstream destination

• Activates diverter device

• Sorts cartons/packages into

different streams

Takeaway • Takeaway Options

- Conveyors

- Chutes, Spirals

- Drops

• Transport / takeaway cartons away

from sorter

• Feed downstream pack stations or

shipping stations


Review of Different Types

of Sortation Systems


Manual - Put Wall Sortation / With Lights

14

Operator scans incoming tote

license plate

Put to Light identifies the cubby

hole to sort product/quantity to

(30 – 75 cubby holes typically)

Confirm by pushing button on

light panel

Product removed from other

side of wall for packing

Typical Applications Pros / Cons / Considerations

Upstream batch piece picking process↑ Provides integrated order consolidation

and packing

Upstream goods to person automation ↑ System-directed manual process

Upstream pre-put picking process↑ Flexible, scalable, mobile (wheels), low

cost alternate to mechanized sortation

Small orders with few order lines (e.g. e-

commerce, catalogue, customer-direct)↓ Limited throughput volume rate


Put Wall Video

15


Conveyor with Right Angle Transfer

16

Powered roller conveyor with 90° bi-directional package

transfer to left or right

Pneumatic lift used to divert package

Standard diverter with pop-up straps has a lower

sortation rate of 25 - 30 cartons sorted per minute

High Speed diverter with pop-up rollers can sort up to 25

- 60 cartons per minute

Requires a flat-bottom entity such as a carton or tote

Typical Applications

Standard diverter handles minimum carton dimensions

of 6”W x 9”L with 2 – 110 LBs at 180 feet/min

High speed diverter handles minimum carton dimensions

of 9”W x 9”L with 2 – 110 LBs at 240 feet/min

Merge batch picked items to a highway lane

Divert / sort items/cartons to picking zones

Medium throughput sortation to shipping lanes


Conveyor With Right Angle Transfer

17


Conveyor with Swing Arm or Paddle or Push

Deflector

18

Powered roller conveyor with 45°-90°

package transfer to left or right

Pneumatic swing arm, pusher arm or

deflector arm used to divert package

Right angle Pusher can sort 25 – 50

cases/totes per minute

Swing arm diverters can sort 25 - 60

cases/totes / minute

Some applications can go higher


Divert / Sort cartons or totes to conveyor

lanes for transfer to new pick zones or to

shipping lanes

↑ Medium cost, flexible and modular

diverter that can easily be relocated

within a conveyor system

Standard pusher handles minimum carton

dimensions of 4”W x 6”L x 2”H with 2 – 75

LBs at 250 feet/min

↓ Higher speed pusher diverters can have

a high impact on the product being

sorted


Swing Arm, Paddle & Push Deflectors

19


Conveyor Strip-Belt Sorter

20

Bi-directional right angle

transfers

Motorized pulley drive with

pneumatic transfer lift elevates

high strength belts

Designed to sort parcels up to

100 Lbs at speeds of 25 - 65

items/cartons/totes per minute

Often used to sort loose units or

totes


Suitable for totes, trays and for rigid form

factor products like CDs, DVDs, returns

sortation

↑ Highly energy efficient

↑ High strength belt

↓ Product weight constraint


Conveyor Strip-Belt Sorter

21


Conveyor Positive Belt Sorter

22

Pneumatic lift mechanism causes

cartons to divert to left or right on a

30° angle

Powered belts face package flow for

diverting

One or two belts used depending on

width of conveyor to reduce minimum

gap requirements and maximize rate

25 - 60 cartons/totes sorted per

minute


Generally applied to low throughput

applications

↑ Energy efficient

Divert / Sort cartons/totes to destination lanes ↓ Limited throughput volume rate


Conveyor with Steerable Wheel Pop-Up Roller Wheel diverter

23

Pneumatic rotary actuator turns wheels

for diverting cartons 30° to left or right

Wheels rotate or pop up to divert

package

Steerable wheel diverter can sort 30 - 80

items per minute

Pop-up wheel diverter can sort 35 - 100

items per minute


Steerable wheel handles min. carton

dimensions of 3”W x 9”L up to 24”w x 36”L

with 2 – 110 LBs at 315 feet/min

↑ Flexible and modular diverter that can

easily be relocated within a conveyor

system

Pop-up wheel handles minimum carton



↑ Range of throughput rates supported


Steerable Wheel Sorter

24


Linear Sliding Shoe Sorter Angle Divert

25

High-Rate Sorter

Aluminum slats (typ. 4”) with

sliding shoes

One sided, 30° sorting

100 – 280 cartons per minute

throughput capacity

Speed of up to 150 to 600+ ft/min


Angled divert handles minimum carton

dimensions of 4”W x 6”L up to 41”w x

48”L with 2 – 100 LBs at 540 feet/min

↑ Possibility to eliminate chain drive, no

lubrication

↑ Electro-mechanical divert switch (no air)

↑ Automatic speed control for throughput

fluctuations saves energy & reduces wear

Applied for high throughput applications ↓ Higher cost system


Linear Sliding Shoe Sorter Parallel Divert

26

Ultra High-Rate Sorter

Aluminum slats (typ. 4”) with

sliding shoes

One sided, 30° sorting

150 – 380 cartons per minute

throughput capacity

Speed range 150 – 600+

feet/min.


Parallel diverting provides the highest sortation

rate & slowest transfer speed

Parallel divert handles minimum carton




lubrication


fluctuations saves energy & reduces

wear

↑ Smaller gap required between cartons

High throughput retail sortation applications ↓ Higher cost system


Linear Sliding Shoe Bi-Directional Divert

27

Mid-Rate Sorter that requires low space

Aluminum slats (typ. 4”) with sliding

shoes

Two-sided, 30° angled sorting

100 - 280 cartons per minute throughput

capacity

Speed range 150 – 540 feet per minute


Applied for medium/high throughput

applications as an alternative to pop up

wheel sorters


lubrication

↑ Electro-mechanical divert switch (no air)


fluctuations saves energy & reduces wear

Bi-directional divert handles minimum

carton dimensions of 3”W x 6”L up to 31”w

x 48”L with 0.2 – 110 LBs at 320 feet/min

↓ Higher cost system


Sliding Shoe Sorter

28


Circular Sortation – Cross Belt Sorter

29

High-speed bi-directional sorter

diverts items or cartons 90° left or

right

Divert points can be at close

intervals for space efficiency

Performs True Positive Active

sortation

Single, twin, double deck and quad

cell


High speed throughput applications that can

handles minimum item dimensions of 3”W x

3”L x 0.1”H up to 24”w x 47”L with 0.2 – 110

LBs at 360 - 490 feet/min

↑ Flexible and modular diverter that can

easily be relocated within a conveyor

system

Diverts units or cartons to destination lanes ↑ Flexibility to sort a wide range of entities

of their shape, size and surface

characteristics


Circular Sortation – Cross Belt Sorter

30


Circular Sortation – Tilt-Tray

31

High-speed chain-driven 2-way sorter

used for a wide mix of unit or parcel

sortation

Wide choice of induction units and chute

designs

Flexibility to scale down throughput

speed to reduce product impact

Speed can range 400 – 500+ ft/min

Can sort 23,000 - 25,000+ pieces per hour

depending on design


Applied where a diverse range of units or

parcels are sorted to destination chutes/lanes.

↑ High-accuracy, high-speed, low-noise

system that is scalable

↑ Modular by design – flexible to change

Commonly used to sort a wide range of

products including apparel, small items in poly

bags, mail envelopes, courier parcels, DVD’s,

CD’s and small to large corrugated boxes.

↑ Handles a diverse range of items and

parcels

↓ Can requires a larger footprint

depending on the design


Circular Sortation – Tilt-Tray

32


Circular Sortation – Bomb-Bay

33


Often used to sort apparel / soft

goods, or small products that can fit

on a tray and that are not fragile.

↑ High-accuracy, high-speed sortation that can

scale to low throughput applications

↑ Less space requirement because chutes can be

directly below the sorter

↓ Efficiency constraints when 4 people induct at

one induction station

↓ Each wave release requires time to reset the

shipping cartons under the sorter

High-speed continuous loop sorter that is

typically an oval race track traveling at ~140 feet

per minute

8 operators can manually induct up to 40,000

pieces/hr at 2 ends of the loop

Also known as a split tray or quad tray sorter

because trays can be divided into 2 or 4 sub-

trays


Circular Sortation – Bomb-Bay

34


Automation – Shuttle System

35

Shuttle robots can be used as an alternative

to traditional sortation systems

Shuttles can stage totes or cartons selected

from one or many pick zones in the DC

Totes are staged and then released for

outbound deliveries in optimal sequence

Heaviest totes can always be on bottom of

pallet for ergonomic considerations


Retail– merge and consolidate totes

from conventional pick areas and

release by store in aisle/weight

sequence

↑ High-accuracy sortation that can scale to high

throughput applications

↑ High storage density / low footprint

↑ High-flexibility solution

E-commerce home delivery for food

– sort by route and stop

↓ Higher thoughput requires more shuttles

therefore more cost


Application Selection Guidelines

36

(8,000 to 40,000+)

(6,000 to 18,000)


Sorter Selection Guide (Throughput)

37

(Cartons/

Hour)

(Cartons/

Min)

Right Angle

Transfer

(Bands)

Right Angle

Transfer

(Rollers)

Pusher

Diverter

Strip

Belt

Sorter

Positive

Belt

Sorter

Swivel

Wheel

Divert

Pop-Up

Wheel

Divert

Sliding Shoe

Bi-Directional

Divert

Sliding

Shoe Angle

Divert

Sliding Shoe

Parallel

Divert

Tilt Tray

Sorter

Cross Belt

Sorter

Bomb Bay

Sorter

25,000 - 40,000 420 - 670

18,000 - 25,000 300 - 420

15,000 - 18,000 250 - 300

12,000 - 15,000 200 - 250

10,200 - 12,000 170 - 200

8,400 - 10,200 140 - 170

6,600 - 8,400 110 - 140

4,800 - 6,600 80 - 110

3,600 - 4,800 60 - 80

2,700 - 3,600 45 - 60

2,100 - 2,700 35 - 45

1,500 - 2,100 25 - 35

900 - 1,500 15 - 25

0 - 900 0 - 15

Legend: Low Fit Med. Fit Optimal Fit Optimal Fit

Mid Rate

Sorter Selection Guide Based on Sortation Rates of a Standard 16" Carton

High RateLow Rate Throughput Rate


Summary of Sortation Systems

38

Sortation

System

Throughput

Rate per Hour

Technology Typical

Rate

Max

Rate

Metric System Cost Flat Bottom

Required

Takeaway Options

Manual Put

Wall

Up to 700

Items/hour

Pick/Put to Light 7 12 Items per min. Low No Pack Station or

Powered conveyor

Right angle transfer diverter

with straps

25 30 Cartons/Totes per

min.

Low Yes Powered conveyor

Right angle transfer diverter

with rollers

25 60 Cartons/Totes per

min.

Low Yes Powered conveyor

Flat belt conveyor with swing

arm, pusher arm, or deflector

diverters

25 60 Items/Cartons/Totes

per min.

Low No All

Strip-Belt Sorter Diverter 25 65 Items/Cartons/Totes

per min.

Medium No All

Positive Belt Diverter 25 65 Cartons/Totes per

min.

Medium Yes All

Swivel/steerable wheel diverter 30 80 Cartons/Totes per

min.

Medium Yes All

Pop-up wheel diverter 35 100 Cartons/Totes per

min.

Medium Yes All

Bi-Directional Divert 100 280 Items/Crt per min High No All

Angle Divert 100 280 Items/Hour High No All

Parallel Divert 150 380 Items/Hour High No All

Cross-belt sorter 350 500 Feet/Minute High No Chute

Tilt tray 350 500 Feet/Minute High No Chute

Bomb-bay (1-tray, 2-tray, quad-

tray)

120 140 Feet/Minute High No Drop, Chute

Automation Shuttle System Customized High No Powered Conveyor

9,000 to 24,000

Items/hour

Conveyor

Diverter

Systems

Up to 7500

cartons or totes

per Hour

Circulation

Sortation 8,000 to 40,000+

Items/hour

Linear Sliding

Shoe


Key Takeaways

Many sortation systems are available on the market and

we have only discussed the more common ones

Sortation system costs generally increase as

throughput rates increase

It is key to identify throughput rate requirements,

packaging format, weights, shapes, sizes of products,

cartons or totes to be sorted

There is an optimal sorter for each type of application

and the guidelines presented here provide a basic

starting point towards this objective


Conference Cloud Additional Resources

40

Put Wall

- http://www.youtube.com/watch?feature=player_detailpage&v=NToQfX3NseQ

Linear Sorters

- http://www.youtube.com/watch?v=2TJ4NYHuXPI&feature=player_detailpage

Conveyor Sorters

- https://www.youtube.com/watch?v=PvLoU9D07s0

- http://www.youtube.com/watch?v=F-ZdQGtaItU&feature=player_detailpage

- http://www.youtube.com/watch?v=pSemAc9s7XQ&feature=player_detailpage

Cross Belt Sorters

- http://www.youtube.com/watch?v=HGkpXNQzZuQ&feature=player_detailpage

Tilt Tray Sorters

- http://www.youtube.com/watch?feature=player_detailpage&v=PM7dRuFmHI4

- http://www.youtube.com/watch?v=_RrU_AAqPtE&feature=player_detailpage

Steerable Wheel Sorters

- https://www.youtube.com/watch?v=PvLoU9D07s0

http://www.youtube.com/watch?feature=player_detailpage&v=NToQfX3NseQ

http://www.youtube.com/watch?v=2TJ4NYHuXPI&feature=player_detailpage

https://www.youtube.com/watch?v=PvLoU9D07s0

http://www.youtube.com/watch?v=F-ZdQGtaItU&feature=player_detailpage

http://www.youtube.com/watch?v=pSemAc9s7XQ&feature=player_detailpage

http://www.youtube.com/watch?v=HGkpXNQzZuQ&feature=player_detailpage

http://www.youtube.com/watch?feature=player_detailpage&v=PM7dRuFmHI4

http://www.youtube.com/watch?v=_RrU_AAqPtE&feature=player_detailpage

https://www.youtube.com/watch?v=PvLoU9D07s0


Questions

41

The Sortation Palooza - MWPVL€¦ · Circulation Sortation Cross-belt sorter Tilt tray sorter...

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