The introduction of an automatic document feed at a key site in Devon has been installed by Keymas. The idea behind the automatic document feed is to automatically generate upon system demand a hard copy of the pick list and insert it into the picking box. The benefits of this are -

-Inserts an order list into the box
-Creates a hard copy for picker if required
-Creates a back up routing barcode

The automatic printing and insertion of the hard copy document mean that should there be a barcode error picking can continue, it also ensures pickers have a back up hard copy for error checking and validation of the picking order.

The Document feed is a development in automated systems and will continue to be used in future Keymas projects around the country.

For more information about the automatic document feed and whether it could be used in your warehouse or distribution centre please contact info@keymas.co.uk

Keymas Launched a brand new website to profile its market leading Warehouse Management Software program K-store. The new site graphically showcases the 5 key elements of the warehouse that K-store innovatively manages, goods in, product put away, stock control, picking and despatch. 

The new website focuses on the benefits of introducing the K-store management system into your warehouse. Combining the benefits of barcode technology with information management software, K-store allows you to improve the performance of your warehouse, cut costs and wastage, improve accuarcy and control and improve crucial business elements of your warehouse such as throughput and efficiency.

The new website graphically shows the benefits of K-store within each stage of the warehouse.

The website also features a simple to use features/benefits list which allows warehouse managers to see what type of application of K-store they need.

For more information about K-store please visit the new website at www.k-store.co.uk

Food. White goods. Automotive. Manufacturing. Logistics. Direct selling. Paper. Pharmaceutical. Clothing.

Working in 9 significant industries in the UK.

Food and beverage – Working in the food and beverage industry
Case study – Ouwehand, Miller Brewing
More info – food production, food Packaging, bakery and confectionery, dairy products, general and large producers, frozen food, catering, meat and fish products, fruit and vegetable, wholesalers, distributors and suppliers, brewery, soft drinks, bottling, container, carton. 

Automotive – Working in automotive manufacture
Case study – Cummins engines
More info – automotive manufacture, parts and equipment manufacturing, distribution and transportation, accessories, mechanical and engineering.

Pharmaceutical and medical – pharmaceutical/medical industries
Case study -
More info – working in biotechnology, distributors, veterinary medicine, warehousing and storage, production and manufacture, supplying and distribution.

Manufacturing and engineering – manufacturing and engineering in the UK
Case study – Continental tyres, carters, Hansen Transmissions
More info – machining, manufacture, storage and distribution, tools and equipment manufacture, technology, computers and circuit board manufacture, packaging, metal, plastics, industry manufacturing, toy, consumer manufacturing. Engineering.

Logistics and distribution – supporting logistics and distribution providers
Case study – Wurth, Frans Mass, Dubolis
More info – Cargo, industrial warehousing, supply chain management support, warehousing, haulage, materials handling, storage, distribution, packaging and re-distribution.

White goods-working with distributors and manufacturers of white goods
Case Study- Lec
More info-white goods importers/exporters, manufacturing and distribution, parts, suppliers and sellers, warehousing, storage, and transportation.

Direct selling – supporting direct selling establishments
Case study -
More info – Catalogue ordering, mail order establishments, online ordering, distributors, next day delivery, telephone ordering, warehouse storage, TV shopping.

Clothing and footwear – clothing, footwear
Case study – Adams Childrensware, ACS
More info – Clothing, footwear, retail, manufacture, distribution, supply. Warehousing and storage, transportation.

Printing and paper – paper based industry
Case study – Field packaging, Kodak and Georgia Pacific
More info – Paper manufacture, paper supply. Recycling, paper materials, tissue manufacture, packaging products, waste paper supply and recycling.

Features and benefits

Keymas’ dedicated team of experienced conveyor system experts brings you the key features and benefits of introducing intelligent conveyor into your warehouse or distribution centre. Whether a simple conveyor layout or complex integrated system intelligent conveyor brings you the flexibility you need.

-Low power consumption
-Easily expandable conveyor lines
-Flexible and cost effective
-Compact and improves use of space
-Complete material handling and distribution solutions including intelligent software controls
-Achieve smoother, efficient material handling and distribution
-Minimal maintenance required
-Easy to install
-Equipped with PTM (Pick To Monitor), the cost effective alternative to Pick to Light system
-Multiple conveyor and heavy duty or high elevation supports
-Designed with safety features

In light of the projected financial and business climate many warehouses and distribution centre’s will be looking to maintenance to successfully equip their current warehouse and conveyor systems for the next few years. Guaranteeing the successful operation of the warehouse and avoiding any unexpected costs or delays is essential considering no company wants to have to pay breakdown costs or delay operations in the current climate.

Investing in long term maintenance provision is as cost effective as you can get and fits a pattern of spending applicable in these times, no large outlays, no capital expenditure and a successfully operating system, what more can you ask for. Many companies will look to engage new and innovative companies to provide maintenance on their system, and provide upgrades allowing expandability in a new way.

Keymas provide maintenance and support packages for warehouse and distribution centre systems. This includes conveyors, AGV’s, WMS, control and applications for pallet, tote and box systems.

Visit www.keymas.co.uk/support for more information.

So that you can get the latest developments and info from Keymas at Logistics Link South exhibition we have launched our very own exhibition website. If you are at the show then this will give you more info about Keymas with videos, photos and the latest case studies to give you more information. If your unable to make it to the show, then this information is available so you too can get the latest updates from keymas.

Visit www.keymas.co.uk/exhibitionsouth

Also, join our newsletter and recieve updates about developments in your industry. www.keymas.co.uk/newsletter.htm

Keymas exhibit at this year’s Logistics Link South exhibition showcasing at Sandown Park, Surrey. Market leading suppliers exhibit the latest technical and practical developments in materials handling and logistics at one of the UK’s most prestigious exhibition venues.

Keymas will exhibit details of automated handling and storage solutions. From simple product conveying, through to fully integrated turnkey systems including AGV’s, supplied with customized controls to ensure full track traceability of production, sortation sequences, through to storage and despatch. 

Keymas will also exhibit the latest developments in our exciting new warehouse management solution, k-store. Taking a modular and selective approach to warehouse management k-store gives you the versatility to manage your warehouse with reporting and stock control capabilities at a fraction of the cost of a full WMS, check out www.k-store.co.uk for more info.

Preparing your operation for 2009

This year we have seen the election of a new US president, the recession of a global economy, and the come back of Take That! But how will the significant events of 2008 affect the logistics and materials handling industry in 2009, and can Logistics Directors, Warehouse Managers and Operation Managers do anything to better prepare themselves for 2009. 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 key issues and considerations for next year.

Question: What have you seen in 2008 that has significantly affected the materials handling and logistics industry?

Barton: I believe the key factor throughout the industry and possibly through all industries that has become absolutely essential is the necessity to adapt. Never before have we seen the industry shift and change at the rate it does now, through technological advancements, changing consumer demand and of course shifting global economy, there has never been a more important time to be able to adapt to the forces surrounding the warehouse.

Question: And how has this affected companies you know and work with?

Barton: Obviously the global economy has really put pressure on businesses to reduce overheads and running costs, particularly looking at cost per item. Everything we buy has a cost. This is made up from three crucial elements, the cost of the actual item, the storing, picking and handling cost, and the distribution or delivery cost. This year we have really felt the true force of external factors affecting prices. And this is why companies must focus on storage, picking and handling costs, as these are the only costs that companies have total control over. We have seen a huge rise in item production costs, especially as China and other countries also struggle with the pressure of the global economy. Distribution costs have obviously been affected by the increase in transport and fuel costs. And it is those companies we have worked with who have focused on the storage, picking and handling of their product that has given them the competitive advantage and allowed them to reduce the cost per item, keeping the selling price low and therefore allowing them to survive and even grow in the current climate.

Question: How have some of these companies you’ve mentioned altered their storage, picking and handling process to give them the competitive advantage?

Barton: Well, we’re working with one company at the moment that has just completed a project to semi-automate their warehouse; they predict already, a cost saving of around 40-50%. Another company we are working with forecast a massive saving of around £3.5 million, simply by cutting their third party off site storage. Cutting out all the costs associated with the running and operation of offsite storage, including transport costs between the two warehouses. It will require an investment of around £1 million, but by cutting the costs the company will in the not too distant future be able to seriously cut their cost per item simply by reducing the storage costs.

Question: How do you see this year’s events affecting 2009?

Barton: I see an even greater pressure on companies to compete as we see the play-out of the world wide economic issues. There will be more pressure for companies to reduce overheads, particularly employment costs. I think there will also be an increase and greater pressure for next day delivery. Customers don’t want to store products anymore because of the costs involved, therefore the pressure is on for quicker and more efficient distribution and more flexible and effective materials handling.

Question: What do you think Operation Managers, Logistics Directors, and Warehouse Managers can do to aid their operation next year?

Barton: I think it is down to Operations Managers, Warehouse Managers, Logistics Directors and others involved directly in the storage, picking and handling process to champion a change. To think outside the box, invest in order to save. There is sometimes great resistance to change. Just because things have always been done a certain way in the warehouse, we sometimes don’t look for alternative, better ways. I think these guys have the responsibility to make the warehouse as efficient as possible, sometimes this means including automated or semi automated processes other times its simply improving their data capture to be able to monitor processes and personnel in the warehouse. Whatever it is, it requires someone to ask the questions, Warehouse Managers, Operations Directors have the best opportunity to ask the relevant questions, and hopefully get the right answers for their business.

Question: Finally, could you outline some of the recommendations you would make for next year?

Barton: Analyse storage operations – so much cost is held up in the way we store things, going through a process of analysing the way we store can reveal very interesting opportunities.

Walk your picking process – slowly analyse and look into your picking process, sometimes operators are working at 20-30% efficiency, there is no way you can compete in the modern business environment with this level of efficiency.

Don’t be afraid to bring someone in from outside – we all know it’s harder to see the plank in our own eye than the speck in someone else’s. Someone outside our operation can see the floors in our processes and hopefully point us in the right direction, don’t be afraid to enlist a consultant or expect in this field.

Finally, look for opportunities for greater return on investment – it can be very tempting to hide away and simply hope the economic climate won’t affect our process. The fact is, it will. The only factor we can work with is our response. Many companies are slimming down, cutting unnecessary costs in order to ride out or even grow in some of the opportunities of the current world market. It is these companies that will survive and come out on top. Your warehouse process can play a huge part in this survival.

A bit about the interviewee – John Barton began Keymas Ltd in the 80s when automated systems were beginning to be used all over the world. Keymas Ltd has worked with companies such as Argos, Amazon and Camelot to develop and improve their storage, picking and handling processes. He also works as a consultant working with companies to improve their logistics and materials handling competitiveness.

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.