Case Study: InterChange Group
Background:InterChange Group, based in Harrisonburg, VA, performs cold-storage warehousing and distribution for major U.S. food producers and other suppliers around the world. To service a local customer at a more strategic-level, InterChange Group needed to increase the efficiency of its cold storage facility and prove to their customer they were able to handle the growing volume well into the future. |
The Challenge:More specifically, InterChange needed to integrate their new fleet of semi-automated forklifts with the Camelot Excalibur Warehouse Management System and increase the efficiency of the warehouse. Deploying the technology investment with temperature and date-sensitive food-products, in an accelerated timeline, presented many challenges. |
Video of the InterChange Cold Storage Operation
Results:
Camelot worked closely with InterChange through a series of discovery calls and site visits to fully understand the automation technology and requirements of the operation. The significant investment in semi-automated forklifts increased the urgency of implementing a fully integrated solution with Camelot’s Excalibur WMS.
There were two parts to the project: 1) integration of the semi-automated forklifts with Excalibur WMS for full-pallet picking and putaway and 2) implementation of the layer-pick operation using a more centralized replenishment system.
Integrating the Semi-Automated Forlifts
The Camelot Excalibur WMS used an intermediary interface to talk directly with the forklift’s onboard computers. As orders are received via EDI from the supplier, Excalibur determines the most efficient pick-location and forklift from which to pull the order. Once the driver has positioned the forklift in the aisle area, the forklift automatically locates and pulls the pallet from the six-level rack and brings it to the order staging area. For any items that are less-than-pallet, the WMS specifies to pick from the layer pick line or another manual pick area.
Layer-pick Line
The layer-pick line is used for order quantities that are less than full-pallet. The WMS has the intelligence to recognize if the layer-pick line or a hand-pick process should be used to fill the order. Using the gravity-fed pallet flow racking system in a centralized area of the warehouse has doubled the throughput, and with fewer people. Excalibur recognizes when replenishment is needed in the flow racking to keep the line running smoothly.
The relationship between InterChange and Camelot is built on trust and a shared focus on growth. Both companies know the importance of understanding the needs of the customer and providing innovative solutions to meet those needs. As InterChange continues to add more space and services, Camelot will be there to help!