Kuecker Logistics Group, Inc.

Case Studies: Convenience Store Chain

Project:	Full case and split case pick modules, conveyor and sortation.	Click on any of the thumbnail photos below for a "slide show" of installation photos
Conveyors:	FKI - Buschman
Spiral Conveyors:	Portec
Scanners:	Accu-Sort Systems
Carton Flow Module:	Unarco Material Handling, Inc.
Full Case Module:	Konstant Products
Pallet Flow:	Interroll
Pushback Rack:	Konstant Products
Project Overview: KLG has recently finished implementing our third distribution center for a major convenience store retailer. Many businesses in this industry rely on third party suppliers for their needs. This company however has been successfully relying on their own distribution for many years and they have been coming to KLG since 1990 for their material handling needs. During that time we have completed 3 complete turnkey distribution centers and over 50 material handling projects. This latest system includes a three level split case pick module, a three level pallet flow pick module a shipping sorter and several thousand pallet positions of racking. In the split case carton flow pick module, candy, grocery and tobacco items are picked into totes on the first and second levels. Cigarettes are picked, stamped and repacked into original shipping cases on the third level. All totes and cases are labeled with barcodes designating the store number and route number. All of these items exit the module on a large accumulation line that merges with the items from the full case pick module.

The full case module includes two deep pallet flow racking on both sides of the pick module. Manually operated pallet separators are built into each flow lane for safely indexing new pallets forward toward the picker. Orders are picked in this module using barcoded labels. One label is printed for each case and applied to the case by the picker prior to placing it on the outbound conveyor. These cases exit the module and travel on a long accumulation line that merges with the split case items.

After merging together the items from both pick modules enter into a 12 lane sliding shoe style sorter in the shipping area. Here the items are diverted into separate shipping lanes in store sequential order for optimal truck loading. By utilizing the sorter the customer is able to employ batch picking in all of the modules for greater picking efficiency. A PC control station in this area includes an HMI screen detailing all conveyor activity and any issues requiring maintenance. Detailed reports are also generated for each route displaying what items are on board the truck for each store.

On this project KLG worked with the customer from the very beginning by designing the material handling system and assisting with building selection based on the material handling requirements.