This article is specifically focusing on the ergonomic operations of this “Pack/ Shipstation” location. There will be three focused areas to review: Process Efficiencies, Ergonomic Impacts and Financial Impacts. Click here for a downloadable copy of this report with detail drawings and photos.
Pack /Shipstations: When shipping product, many companies need to have a final process step to get the product out the door. This step can include Quality control functions, Re-packing, void fill, packing slip / literature insertion, sealing the box, applying one or more outbound logistics labels, closing out that order (job ticket) in the system to name a few.
Process Review: In many of the applications, product is brought from the warehouse to a central area. Pack Shipstation, Ship Manifest, Order Closeout are all typical names for this area.
A very basic process for this could be the same operator who picks the product to the order could complete the entire process resulting in a shippable package. More complex processes separate the processes into specialized operations. This can be done with the same operators via accumulation (stacking the orders, dropping off a cart, etc.), then flexing the staff to process all the accumulated orders in a type of slug mode.
Even more complex operations use automated systems for the completely picked order to be brought to the packing/QC/Manifest areas. With these individual stations can be identified by work to be performed. For example, workstation operations could be sorted by QC requirements, outbound shipping destination, size, weight, customer, etc.
Based on the customer’s throughput needs and specialized outbound logistics requirements, a Semi-Automated process was selected. With the use of automation, a high-level view would require the automated system to bring product into a pack station and then move the completed shipping cartons back out of the pack area. There are three common ways of doing this. Although there are multiple variations to these processes. These are typical for local pack station / automated system interaction.
Multiple elevations:
This option would have a two-tier accumulation system that brings inbound product from the picking area in on one level, the outbound logistics to the shipping/pallet build/direct to container area on the other level. One issue with this concept is that it is not ergonomically friendly as product must be lifted or lowered to a second level tier.
A solution would be 90-degree transfers to decline accumulation with discharge on the back side of a pack station. Although this reduces the ergonomic impact, the costs are significantly higher.
Pros:
- Egress and ADA compliance easily satisfied.
- Smaller footprint required in the customer’s location
- Depending on application can be cost competitive.
Cons:
- In some applications product coming into ship area is above operator’s view.
- Weight of product can be an issue
- Reach/extend requirements may limit which operators can work these positions
- Not easily ADA compliant due to reach/extend.
- Depending on the application can be cost restrictive.
Pass across the pack station:
Another way to do this is a with inbound accumulation (typically powered conveyor) on side of the operator, outbound transportation (powered conveyor) on one side of the operator and a pack station between. The issue with this layout is that you have the operator “land locked” in the middle and need a gap to allow access. Egress is required for operator safety. No one wants operators climbing over or under conveyor. Some locations require ADA access to all work locations. The egress can be handled in a few different ways.
- 1. The operators can carry product over the gap or across a gate. (typically, not powered)
- 2. A gate can be placed in the takeaway section. (Typically powered)
- 3. Ladder style crossovers can be utilized. (Does not comply with ADA access)
One other significant issue with this application is the restocking of materials to the pack stations. Boxes, tape, dunnage will need to be physically manipulated to restock the pack stations. Due to the land locked nature of the layout, it may not be as convenient to maintain the cleanliness of the area.
Pros:
- Weight of product may not be an issue.
- Damage to product is minimized.
- Depending on application can be cost competitive.
Cons:
- Egress and ADA compliance cannot be easily satisfied.
- Larger footprint required in the customer’s location.
- Weight of product can be an issue if operators are to carry product across gap.
- Issues with Egress remain.
- Restocking the pack stations can be cumbersome.
In-Line Pack Stations:
Another way to do this is a with inbound accumulation (typically carts, gravity, or powered conveyor) directly into the end of the pack station. The operators will manipulate the product onto the workstation, perform all the functions, then pass onto a downstream outbound destination. This can be direct to the pallet, onto another conveyor for sortation or to a conveyor system for downstream pallet build.
This application can be very effective in smaller volume applications or applications with almost no variation in outbound shipping method. If the goal of the project is to reduce walk space and reduce operator dwell time, this may become a rather expensive option due to sortation requirements, routing to specific workstations, etc.
If the operation is a very high volume with multiple outbound destinations this may be the best alternative. This also comes with a significant price tag but can be cost effective.
Pros:
- Weight of product is not an issue.
- Damage to product is minimized unless using a Cart/pallet to stage product for ship processing.
- Depending on application can be cost competitive.
- ADA and Egress are typically not an issue.
Cons:
- Larger footprint required in the customer’s location if more than 2 pack stations are required.
- Sortation and accumulation equipment and controls can significantly impact the cost effectiveness.
- Throughput restrictions, accumulation required, takt time of shipstation process all need to be reviewed to determine if this is a viable option.
For a recent project System in Motion came up with a different approach.
The application called for us to design and install a new accumulating system to feed 4 shipping stations. As product comes from stock (picking operation) to the pack stations, the shipping operator is responsible to pull the item and place on their individual packing station. This specific customer’s process included: selecting an outbound shipping box, arrange the product via “Tetris” style packing, include dunnage / void fill, weigh, enter and print all the shipping paperwork, manually seal the box to be sent to shipping area. At this point, it is similar to the above-mentioned processes.
We discussed the options for multi-level and egress issues with the customers operations, engineering, and safety departments. As with most projects, cost and ergonomics were significant factors in the decision. The customer\’s operation and safety departments had issues with back strain and operator movement with the multilevel approach. The restock, local codes, and the egress were of very high concern with the corporation’s safety standards for the Pass Across option.
Due to the need for 4 pack stations and the volume required, the inline option would have been both cost and space restrictive for this application.
Working with the customer’s engineering and operations staff we looked for a solution to easily push the completed packages from the scale on their workstation to an outbound conveyor on the other side of the inbound conveyor.
The Solution – Pop Up Skatewheel Transfers to a central takeaway conveyor.
To stay within the customer’s budget, space, throughput, and ergonomic concerns, we decided to implement a gravity skatewheel transfer with a foot actuated electric rise. This system is essentially a 3 strand, between rails, timing belt transfer. Because this transfer was to be gravity (non-powered) only, we were able to eliminate the timing belts, the 24 Volt DC Drive Motor, and Control Card to drive the transfer. The customer also did not have a source for air, so we utilized a 24 VDC electric operated lifting device.
Figure 1 – Skatewheel Transfer in Raised Position
Figure 2 – Skatewheel Transfers in Lowered Position
Operation of the system:
Inbound product would accumulate between the workstations. Once an operator’s station was clear another order (tote in this case) would automatically index to position itself for the operator to use. The operator would tap the foot activated switch. The transfer would raise the product to the same elevation as the workstation. The operator would pull the product off of the accumulation conveyor and begin the process of Order Closeout.
Once the order was finished being processed, the operator would tap the floor mounted pedal to lift the skatewheel. The skatewheels will lift to the same height as the customer’s weigh scale. The operator will simply push the completed shipment from their scale over the skatewheel transfer and onto the outbound conveyor to be taken to shipping. The controls of the transfers are set to hold in the up position for 5 seconds and lower to default position. Once lowered, the system would then repeat itself and index the next tote to this operator station.
When the workstation is busy, in process of final packaging and close out of the order, the transfer would automatically index to the lower position to allow other totes flow across the transfers to make way to workstations downstream.
Each workstation was designed to have accumulation available at each transfer. The system would manipulate the totes to keep the accumulation zones full and ready to be processed by the operation staff.
This project was a significant improvement in the units processed per labor hour as well as satisfied all the safety concerns within the corporation. In addition, as the company grows in volume, we will be able to extend the system without significant impact to the existing process.
For more information on this application in Indiana, contact Ryan Carmen – Senior Applications Engineer at rcarmen@systeminmotion.com . Additional information is available at www.systeminmotion.com. We have locations nationwide to review your application, call us at (847) 923-6900 or email: sales@systeminmotion.com
