ID Parcel & Mail Solutions recently developed a custom Sort to Lane software system for a national manufacturer of kitchen and bath cabinets. The new system was first implemented at the Client’s headquarters where they process and ship large cabinet orders. The goal of the system is to efficiently and accurately queue packaged cabinets by customer order prior to palletizing. It also helps the client to validate the process and benefits of implementing an automated large parcel sorting system in the future. The Client has now ordered two more Sort to Lane Systems for two of their other facilities.
As cabinets are assembled and moved down a conveyor line, the cabinets are boxed and labeled. At the end of the line the new system has the operator, with an Effon wearable ring scanner, scan a 2D barcode with the order number and SKU. The system then, using embedded logic, assigns the order to one or more sort lanes to queue up for the other SKU items in the customer’s order.
ID Parcel & Mail Solutions’ custom designed user interface displays the lane number, on both a 24-inch monitor at the end of the conveyor line and on an 85” monitor mounted over the work area for easy viewing. Each item is to be sorted based on volumetric data and number of pieces in an order to allocate lanes. Accessories for the order are assembled and scanned into the Sort to Lane System as well. As more cabinets arrive at the end of the line, the Sort to Lane System tracks which remaining items are missing and allows operators to see what pieces are still needed to close the order.
The benefit of the new Sort to Lane system is that operators don’t need to remember where to stage items and are immediately informed when an order is completed and can proceed to shipping. This efficiency translates into quicker goods movement and better utilization of limited floor space. The operator then moves the item to the assigned lane.
Six lanes and an overflow lane have been established and taped off at the end of the conveyor line on the warehouse floor. The 85-inch TV monitor also displays the status of each lane, the order number assigned to it, and the missing number of items for the assigned order number.
When all cabinets are scanned into that lane, and all accessories for the order are kitted and scanned at the Accessories Station, the software will change the order & lane status so the operator can call for the order to be palletized, thereby freeing up the lane for another order.
Once an order is completed, and a lane is ready for palletizing, the large screen will display a message to close and clear the lane. Upon scanning a 2D barcode on the lane after clearing it, the software can begin allocating a new order to that lane. Special logic is included for small orders and orders that require multiple lanes including the overflow lane.
ID Parcel & Mail Solutions’ software design interfaces to the Client’s warehouse management system (WMS) via a shared access SQL database that is stored on the ID provided computer. The solution includes a Windows 11 Pro computer that is connected to the two monitors and the Client WMS for order and SKU information, as well as a computer and smaller monitor for the Accessory Station.
The main goals of this new system are to provide faster, more accurate sorting of orders and to ensure that all components of an order are in place prior to palletization. The monitors clearly communicate lane placement for items, which will result in faster operator processing and reduce the chance of inaccurate sorting of cartons by job. It also ensures more efficient use of floor space by making order staging more visual and informative, thereby allowing quicker order finalization.
The new system also provides the Client with a low-cost solution for validating the idea of moving to a fully automated order sorting system. Additional automation components could include automated barcode labeling, overhead barcode scanning, and automated sorting conveyors.
As with all ID Parcel & Mail Solutions’ automation projects, we recognize that no automation investment will achieve the desired return on investment if the Client does not have the support and training needed to operate the system at its peak efficiency. As a result, we have provided comprehensive training, and ongoing support to the Client’s staff.
Training of operators is critical to the success of any automation project. ID Parcel & Mail Solutions trained the Client’s leading staff on all aspects of setting up and operating the Sort to Lane System and on any minor maintenance tasks required to maintain optimal operation.
Although ID Parcel & Mail is available for as needed maintenance, the Sort to Lane System is a very robust design that requires little ongoing maintenance except for the minimal data cleanup several times a year to keep it operating properly. Technical telephone and internet support are available if needed.
This project is a good example of the flexible nature of ID Parcel & Mail Solutions’ offerings. This unique Client challenge required a tailored solution. Because of our experience designing and building flexible automated parcel sorting systems, we were able to develop a system from scratch to service the Client’s very specific needs. If you need help making your operation run more efficiently, please reach out to our team.