The six stages of planning when considering a development in your logistics or materials handling operation.

1. Consider the end before the beginning.

Any project that is going to be successful must have clear aims and objectives. Businesses often begin with a sense of purpose then quickly fall into the trap of micro-management and a ‘needs must’ mentality. If your project is going to be successful the aims and objectives must be clear at all times. Questions like, ‘why are we doing this development?’ and ‘What will this adjustment result in?’ must be answerable by all those involved in the process at all times. Keeping the answers to these questions at the top of your list is an absolute must.  

2.Analyse the environment

We all have to consider the environment we are based in. This is linked essentially to resources. What financial resource is there? What human resources are there? What capital resources are there? It’s key to consider this in terms of opportunities. Look around your environment and locate the opportunities for your development. Think, how can we make our development successful considering the environment we are in.

3. Consider your options

Remember not to do this stage first. Many managers will decide they want to develop their system then go straight to google and start searching for options. This often leads to sourcing companies, software or hardware that they are not sure if they even need. Patience is key here. Consider your objectives, your environment, then begin looking for partners, considering those who would best compliment your strengths. Ultimately, those you partner and work with will have a huge influence on the projects success.

4. Plan the project

Sitting down with the partners and suppliers you have considered in stage 3. Plan to your needs, plan to your resources, plan to accomplish stage 1. Each project and each situation is unique. Tailoring your plan to your objectives whilst considering your resources is essential at this stage.

5. Implementation

If the previous 4 steps have been completed carefully, then this stage should run fairly smoothly. However, there is always the opportunity of something unforeseen taking place. This is when it is important to re-plan. Don’t be tempted to fire fight, take care and apply the 5 steps again to the current circumstances.

6. Now evaluate, and learn

Arguably the most important, and most forgotten stage of the planning process. As a business you are aiming to build competitive advantage, become more resourceful and more successful, this is largely dependant on how we learn, and how we develop our operation. Learning from the successes and failures in step 5 will determine the success of the next project, and even the ongoing success of the current project. As with all planning, these six steps are not a one time only, they are a continuous process, how effectively you evaluate and learn, will determine how effectively you carry out steps 1-5 in the next project. Successful learning determines a successful project.

James Cropper Plc a leading manufacturer of a wide range of specialist paper products, invited Keymas Controls and Automation to tender for the creation of a new raised production area and pallet handling method. After surveying the site and observing the restrictions on available space, Keymas presented a proposal that would create additional floor space by utilising the existing building height to the full and positioning a new mezzanine floor over the top of an existing mezzanine.

Previously a fork lift truck could service the needs of the first floor mezzanine, but the additional height demanded a much safer alternative method for handling pallet loads, and a two stage pallet elevator was installed to link all floors to ground level. Required to smoothly transport heavy loaded pallets of different sizes, the elevator is fully guarded and fitted with safety features to protect operatives. The drive unit is fitted with an overload device which holds the pallet elevator in position should a fault trigger the safety device, and sets of limit switches at the various levels ensure stability of load as the motor is automatically slowed to a pre-set stop position.

The time for manufacturing and delivery was very tight, as Croppers had a restricted installation period scheduled for over the Christmas shut down. The system had to be completed within this ‘window’ to avoid disruption to ongoing production requirements. Apart from various structural difficulties they encountered on site, by liasing closely with the customer throughout, Keymas did complete the project two days behind schedule but to the complete satisfaction of the client.

In the latest of a series of articles from members of the Automated Material Handling Systems Association (AMHSA), John Barton, Managing Director of Keymas Ltd, examines warehouse management systems.

 At the fall of France in 1940, the French had over two thousand modern fighter planes - more than twice the number deployed by the victorious Luftwaffe. The problem was that the French administration didn’t know where most of them were. The German Blitzkrieg attack had led many local commanders in France to make tactical decisions to move aircraft, men and equipment south, away from the invaders. These parochial decisions had no easy way of becoming known centrally, with the result being chaos and capitulation. Acolytes of the military theorist Carl von Clausewitz will know of the parallels that exist between military and business strategies. If only the French had had a management system that allowed lower-level local commanders to input information, then those at the top could have made decisions and acted upon it.

WMS is not the full answer

In the modern logistics industry, we have software information systems known as warehouse management systems (WMS), which perform a vital role but are not the full answer in a dynamic business environment. Much WMS software is highly sophisticated and its strength is, in essence, that all information goes into the centre and the WMS ‘runs the business’ from the top down. Perhaps it should not be called a warehouse management system at all, but rather a business management system, as its remit is so wide. There can be a similarity between a modern WMS and what happened in France in 1940, if the lower levels cannot input information. Such input is normally achieved by utilising subsystems that run particular aspects of the logistics solution. The strength of WMS - its central input of information - can also be a weakness, if relevant information cannot be input at these lower levels. Important considerations here include: if there is a problem centrally, will the whole system shut down? Can subsystems add information that the central WMS will accept?

Subsystem control is key

Let’s call these subsystems SMWs (Systems that Manage the actual Warehouse) and let’s visualise them as a local warehouse foreman or manager. Local management makes decisions based on transient factors such as heavy snowfall or a local dock strike - not the distant board of directors. With local knowledge, the site management is best placed to make such tactical decisions. So the ideal logistics solution is one with a WMS that looks after the strategic, commercial aspects of the business - such as the databases, the commercial parameters and the financial paperwork to cover invoicing and billing. Under this, one should consider having tactical subsystems that look up to the main WMS and make it an effective and efficient system as a whole. The advantage of this kind of setup is that there is less electronic traffic on the system in terms of information interchange. The WMS does not have to cope with all the minutiae of logistical movements.

Plan subsystem control at the outset

When considering WMS, one size definitely does not fit all! Many subsystems that will each control a material flow function - such as a miniload crane or an AGV - can be added onto the WMS until it is a comfortable fit for the business at its local level. We could therefore prophesy that the best solution will normally be an efficient, strategic WMS supported by as many tactical machine control subsystems (SMWs) as are required to make the whole system buzz. To extend this to a rule of thumb, one needs to consider the tactical subsystems at the same time as the strategic WMS - never afterwards.

Check out www.k-store.co.uk for information on Keymas’ System to Manage your Warehouse

Phenomenal growth through their retail store expansion programme and increasing Internet orders meant that Argos, part of leading UK home and general merchandise Home Retail Group, needed to review regional operations in their goods supply chain. They looked to materials handling and logistics specialists Keymas for a solution.

In 1989, Argos installed and commissioned a completely new warehouse in which Keymas played a major role, putting together not only the basic concept and overall layout for the warehouse in Bridgwater, Somerset, but also the specific detail that was required to allow the automated conveyor system to operate. The whole system was conceived and designed with Argos to be more efficient and produce better productivity than conventional warehousing at that time and was installed within a twelve month window.

This warehousing system consisted of conventional racking and racking which allowed semi-automated cranes to place and retrieve bulk pallet loads from storage. Selected pallets would be transported on the automatic conveyor system to be located in a sub-system, where semi-automated cranes off-loaded pallets into pick locations for operators to order pick individual items for despatch to various stores in the region. Over the years, Keymas undertook several modifications to enhance the system and provided full support in terms of maintenance and service.

New warehouse system to meet Argos growth

Due to the growth and success of Argos the business required a development of their Bridgwater warehouse operation; one of a network of nine distribution centres Argos currently utilises across the UK. The Bridgwater regional distribution centre (RDC) is essential to the operation of the business, supporting regional deliveries to 89 Argos stores in the South, South West of England and Wales. At the time, work was required to increase its throughput capacity in order to support the Distribution network.

The excellent working relationship built over 17 years between Argos and Keymas meant Argos felt confident in approaching Keymas with a view of establishing some initial cost parameters.

After careful deliberation, Keymas recommended and Argos agreed that a more conventional warehouse arrangement provided the most cost effective and flexible warehousing solution to meet both their current and future needs. This proposal utilised conventional racking and forklift trucks for handling of pallets.

As 89 of the 700-plus UK Argos stores rely on the Bridgwater RDC to receive customer orders, it was not possible to close down the premises in order to facilitate the changes without disrupting its constant flow of operation. Keymas was charged with the task of dramatically changing the warehouse operation - from a crane driven storage system to a manually operated truck storage system - turning the flow through 900 whilst maintaining functionality of the existing warehouse and installing the new facilities.

Argos awarded Keymas the contract

With the help of several partners, Keymas put forward a proposal which included the removal of existing equipment and staggered de-commissioning of cranes to enable the existing facility to continue to operate, whilst the new system was installed. The project also included for the de-commissioning of a multi-level pick mezzanine floor area, which consisted of four individual levels and had to be dismantled in stages.

Argos agreed to the proposed time schedules and budget costs and awarded Keymas the project contract.

Keymas chose their partners carefully, using existing engineering suppliers and their sister company Raxel - specialist in storage and racking solutions. As part of the project management task, Keymas had to also oversee the installation of a sprinkler system and complete new lighting facilities.

To aid this operation, Argos reduced the amount of product movement through the existing warehouse to complement the phased installation requirements of the new build. Keymas and partners worked closely together with the customer’s project management team to ensure men and materials were fully co-ordinated onsite. Regular site meetings monitored progress, reviewed health & safety issues, CDM and compliance with design regulations.

The project was to provide a complete new warehouse package which would facilitate and support the customer moving forward and contribute to a functional storage and logistics system that would be flexible, operate more effectively and efficiently within the distribution arm of Argos.

Keymas Managing Director, John Barton reported, “The project was obviously very challenging at times, but through the close working partnership of all those involved, this was completed with minimal disruption to Argos operations, within budget and well within the allocated time frame”.

For more info on Argos visit www.argos.co.uk
For more info on Keymas visit www.keymas.co.uk

The two busiest weeks of the year leading up to the Christmas rush and the automation system fails.

No one likes to think about the inevitable but technology breaks down, it wears and fails leading to an inoperable distribution centre.

Keymas endeavours to make the fore mentioned scenario something you never have to deal with guaranteeing your distribution operation is as steady and secure as possible. This is why we work with you to develop a maintenance and support programme that suits your operation. Each programme is bespoke and ensures you receive all the support that your operation needs.

Do you support systems you haven’t installed?

The answer to this is on the whole yes. We will assess your system and ensure we are the best placed providers to deal with your requirements. If we feel we can provide the best support then we will work with you to develop a maintenance and support programme.

What parts of my system would you cover?

Keymas specialises in automation systems. This is the area we will specifically focus on. However we are a full system provider and therefore through some very carefully agreed partnerships would be able to support the majority of your operation.

I have a full time maintenance team, do I still need a support and maintenance programme?

This truly depends on how specialised your team is. We highly recommend operations with general or part specialised support teams still work with us in terms of ongoing support. We know automation systems, often it is more efficient, safer and often less expensive to get in contact with us rather than have your team search through software and electronics they are not specifically trained in. We will work with your teams to ensure you get the best support.

Do I really need support?

You can answer that question. We offer you the peace of mind to know you have an efficient system, that your system is regularly checked and if something occurs the easy option to call someone specialised in the field.

Sandown Park (Surrey) proved an excellent location for this years Logistics Link South exhibition. The show was a bustle of exhibitors and delegates from every part of the supply chain and logistics industry. Keymas co-hosted their Logistics Link South stand with partners The Storage Equipment Centre (SEC) to offer a complete warehousing solution.

The show was a resounding success with Keymas exhibiting along side the biggest names in the logistics industry. To find out more about the exhibition, see what was on offer and see the brand new product videos as well as pictures from the exhibition visit our Logistics Link South online exhibition at www.keymas.co.uk/exhibitionsouth.

Keymas to exhibit at the South’s biggest logistics exhibition, Logistics Link South. The show promises to save you months worth of research as in one visit you can get face to face with industry leading suppliers and get up to date with the latest industry developments. At Sandown Park on 5th and 6th February “you will discover the latest supply chain products, systems and services to help optimise your company’s warehouse and fleet operations for the coming year” and get an opportunity to meet over 100 suppliers of supply chain products and services.

Keymas will be exhibiting their exciting new partnership with The Storage Equipment Centre Ltd. Where the combined services offer a fully comprehensive solution to supply chain and warehouse logistics.

As we are excited about our exhibition in the South, until the end of January we are offering free tickets to anyone who contacts us with an interest to see us at Logistics Link South. There’s even an opportunity to receive a pen knife gift if you register before 1st February. So contact us now and receive your free complimentary ticket worth £20.

We demand our products now. Next day delivery is a necessity and inaccurate delivery is no longer an option. But what kind of implications does this have for the sortation system within the supply chain. John Barton, Managing Director of Keymas, with 21 years of industry experience with successful systems in Argos, Amazon and British Airways, talks us through the latest developments in sortation systems, and highlights key points which can transform warehouse and distribution operations.

Question: Could you talk us through some key innovations that are changing the way sortation works?

Barton: Well, really this depends on what sector you’re in…what you’re using for product identification… and how you are sorting. The key innovation I see that is really shaking up the industry at the moment is the low cost and speed of computing power.

Question: How does this affect sortation technology?

Barton: With advancements in the speed of computing power we can now get away with some really clever stuff with our software, which in turn allows for the development of designs and capabilities in the hardware which just wasn’t possible a few years ago. Now, with the advancements in computing power and software we can 100% track the product through the sortation system, where at one time this would be extremely costly, or just not possible.

Question: How can operators ensure they get the all important return on investment?

Barton: As always certain questions need to be asked in order to ensure return on investment is truly achieved. I would suggest one obvious but crucial question to ask is; what is the operator Sorting? Is it boxes? Mail bags? Or perhaps Uglies (industry term for things that cannot be conveyed easily)

Then, once parameters for the product have been set the operator needs to consider who they will involve in the system development. When considering this the operator needs to move away from involving companies that specialise in one type of sortation technology, such as tilt trays, Bombay sorters etc. Without question these companies will be driven by the need to sell that type of technology. Therefore I would suggest that the best way an operator can ensure they get the best return on investment is to use a company which specialises in the most common and general element of sortation systems, the software, therefore using a company that specialises in sortation software and doesn’t have a drive to sell a particular type of sortation technology. I think this will go a long way in ensuring the operator achieves a strong return on investment.

Question: How should companies choose between different systems that are available to them?

Barton: This really is the 64 thousand dollar question. It ties in really with the previous question, as if you bring in a company that sells tilt trays, they are geared up to sell those kinds of systems and they will make sure that they can prove that this is the right sortation system to implement. Of course, in practice, it may not be the most efficient, or may not be the best system to put in. Again, I would suggest that companies look at someone who’s independent, and again specialises in the most common element of a sortation system, the software.

However, a particular product may guide the system down a certain route. For example, if you were sorting mail bags, it would be unlikely that you would put this on a roller conveyor, likewise if you were sorting boxes, it would be unlikely that you would put this on an overhead chain conveyor, I say unlikely because all things are possible.

So the simple answer is, look at the solution, but look at it with a company that understands the concept of the solution but is not geared up to selling one particular technology.

Question: In what industries do you see sortation technology growing and developing? Where do you see sortation technology in 5 years? 10 years?

Barton: One of the biggest market growths I’ve seen concerning sortation technology is in the parcel sortation and deliveries industry. With the growth in the Internet and the demand and drive for next day or even same day delivery we now need to sort things extremely accurately and extremely quickly to respond to customer demand. I would say the innovations in sortation technology has allowed parcel companies and third party distributors to move into areas where maybe 10 or 20 years ago they couldn’t possibly afford, technology has brought the cost of sorters down yet reliability has gone up.

Also benefiting this market sector is how technology now handles information. The idea of having information on a particular product that is being sorted, not just a sorter box or package, but to actually have information tied to that particular product, the customer name, the destination, weight, size etc… and the way things are going weight and size are becoming much more chargeable than they ever have done and having the technology to automatically check the size and weight of a product as its being sorted, not manually at the start, but as it is being sorted along with technological advancements in sensors and scanners is causing sortation developments and investments within this industry sector to really take off. So even now, not to mention 5 to 10 years, we can track accurately and precisely intricate information about a product all the way through the warehouse.

Question: Can sortation technology improve other supply chain operations?

Barton: All the way through the supply chain really, right from manufacture. What if a particular product in its delivery box or packaging actually had its own unique number? And that number could be followed all the way through the supply chain? So we could have track and traceability on the product right from point of manufacture and packaging right the way through to point of delivery, allowing it to be sorted easily, to have all the information allied with it, to have its routing, destination, the timing, where it is, who handled it, what lorry it was on, which despatch lane it was in, and to be able to access any of this information at any point in the supply chain process could radically improve many companies distribution efficiency and productivity.

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It was the North of England that Keymas chose to exhibit its latest service and product updates. Logistics Link North ran for two days and saw logistics and distribution experts from all over the country presenting the latest developments in the industry, as well as seminars in order picking and warehouse innovation the show contained live demonstrations and interactive product showcases.

Keymas presented to industry wide delegates its new prestigious partnership with worldwide logistics experts Egemin, who also took part in the exhibition. Keymas also presented its industry leading products and services including latest developments in order fulfilment, Warehouse Management Systems (WMS), supply chain solutions, automated conveyor, control systems, sortation systems, pallet conveyor, mezzanine floor, and leading complete turn key packages.

For more information on the show click http://www.logisticslink.co.uk/

For more information on products and services which can transform your logistics operation click www.keymas.co.uk

Keymas launch new warehouse control system with name k-store. The website is www.k-store.co.uk read more on the k-store website.