Portwest, one of the world’s fastest growing online workwear companies, has successfully commissioned a new fully automated storage and retrieval system (AS/RS) at its Barnsley distribution center in the UK. Designed and installed by Japanese automation specialist Daifuku, the system replaces what was previously a completely manual fulfillment process, transforming the company’s ability to meet demand for its products.
Following the implementation of Daifuku’s four-crane AS/RS system, Portwest has increased its productivity levels tenfold. Glynn Clyde, Global Head of Warehouses and Logistics at Portwest, explained: “Prior to our adoption of automation, our order fulfillment process was entirely manual. In practice, this meant we could process no more than 30 boxes per hour. With our new automation system, we can now process 300 picked boxes per hour. This was a very labor intensive process. The move to automation has changed our entire operations.”
Automation has significantly reduced the rate of selection errors, thereby increasing service levels and customer satisfaction. This clearly demonstrates the positive impact that automation can have on UK warehouse productivity.
Fully operational by the end of summer 2024, the new warehouse automation system at Portwest’s 15,000m² facility in Barnsley has more than doubled handling capacity, enabling the company to meet anticipated demand for its products, which include high visibility jackets, PPE kits and safety gloves.
Importantly, there were no layoffs within the company, which from the start wanted to prove that investment in automation could be used as a springboard to further growth, as well as more rewarding roles for staff.
Automated high bay storage
DaifukuThe AS/RS comprises four high-bay aisles served by four automated twin-fork Mini-Load cranes. The high-density racking creates more than 76,000 unique locations within the upgraded facility. At over 130 meters long, the Portwest racking installation is believed to be one of the longest installations of its type in the UK.
A key feature of the system is its double-depth design and the cranes’ ability to store and retrieve two crates simultaneously. This allows for greater storage capacity while providing high throughput, thereby achieving greater efficiency in the warehouse.
Technology in operation
Simply put, the Portwest operation operates based on a central feed of cartons, which are transported to the appropriate areas (A, B or C) of the high bay storage racks, depending on their demand profile. Daifuku worked closely with ULMA, its preferred European partner, to develop and install all feed transit conveyor systems.
Piloted by a tailor APIthe conveyors interface with Invar’s software, which in turn communicates seamlessly with the customer’s well-established M3 system.
Daifuku’s four cranes, at the heart of the Mini Load system, are very versatile and can handle plastic containers, trays or, in this case, cartons. With nearly 60 years of experience and more than 34,000 stacker cranes manufactured, Daifuku AS/RS are globally respected for their reliability and quality. Additionally, through updates and development over the years, cranes have become lighter and use smaller motors, reducing power consumption.
When called, boxes are delivered from the AS/RS facility to one of three lines:
- Way One – these items restock the adjoining Autostore, which serves takeout and curbside orders.
- Lanes two and three fulfill bulk customer orders, providing cartons for further shipment via next day delivery.
Russell Hutchinson, sales director at Daifuku UK, said: “One of the benefits of this system is its simplicity. Once a consignment of goods arrives, all operators need to do is enter a carton into the system and we will do the rest. As long as it has a barcode or label, our automated storage system stores it until it is needed.”
Automation for the Nation
Portwest’s experience demonstrates that the right technology within the intralogistics function can transform the efficiency of manual handling processes. The company’s adoption of warehouse automation has significantly reduced picking errors, doubled capacity and also created new roles at its South Yorkshire site.
Clyde continues: “This exercise was never driven by a desire to downsize, because it is people who make our business thrive. We have demonstrated that thoughtful use of automation can deliver operational efficiencies, while creating new, more rewarding roles for people within the organization.”
Portwest – Automation Highlights:
• The 76,000 storage locations are served by four Daifuku cranes, each operating its own Mini Load AS/RS system.
• Based on 80% utilization, this system can handle 2,400 cartons on a double cycle basis per 12 hour day.
• Each M Shuttle has been designed to handle boxes. Using extendable side plates with movable pins at both ends, two cartons can be moved to and from the desired location simultaneously.
• Boasting extended arms, each shuttle also facilitates the use of double-depth storage, increasing system productivity.
• The AS/RS system is controlled by a bespoke WMS system, which integrates with Portwest’s current Infor M3 ERP software.
• At 130m long, the Portwest high bay rack is considered one of the longest in the UK. It houses 76,000 locations.