(Commonwealth) _ When Samworth Brothers, a company based in Leicester, sought a new hanging sign for its chilled distribution site, they opted to collaborate with inotec, a specialist in providing customized warehouse labeling and line marking solutions. The outcome of this collaboration is an inventive ‘docket grab’ hanging sign, utilizing ball bearings to secure dockets. These signs, available in single or double-sided configurations, are now in use in the pick-by-line area at Samworth’s Oak Meadow facility.
The Oak Meadow site in Leicester, belonging to Samworth Brothers, boasts a storage capacity exceeding 10,000 pallets for chill, deep chill, and frozen goods. Approximately 580 individuals are employed on-site, and the picking of orders is managed by 160 warehouse operatives. Glyn Maude, General Manager of Samworth Brothers Supply Chain, elucidates the necessity for the new sign, stating, “As our business has experienced rapid growth in recent years, we needed to revamp our order-picking processes in this warehouse. Originally, the entire area was racked, but a decision was made to dismantle part of the racking, creating a dedicated pedestrian-only picking zone enclosed by barriers.
“This alteration allowed us to present products to the pickers in that area rather than having them retrieve items from the racking. The lanes of pallets extend toward the racking zone, with stock entering the picking area from beneath the racking, delivered by forklift trucks.” Recognizing the need for hanging signs in the new area, I anticipated challenges finding suitable options in the market. Observing other companies using cut drainpipes for labeling, I felt there had to be a more efficient solution. I reached out to Steve Towler at inotec, whom I already knew from previous collaborations on line marking and signage for our marshalling lanes in Leicester. Steve, familiar with our requirements, took on the task of designing the hanging sign when I provided the size and specifications needed. The result was the innovative ‘docket grab’ concept. Working closely with inotec, a few mock-ups later, and we had our customized hanging sign. What sets inotec apart is their assistance in planning and designing, providing honest and accurate cost quotations, along with valuable advice. The concept of using ball bearings to secure pallet labels was entirely inotec’s contribution.
In the pedestrian-only zone, the picker employs a hand pallet truck to collect the pallet of stock and walks down the picking line of pallets. Scanning the pallet label held in the hanging sign above each pallet reveals the details of a retailer’s order, specifying the number of cases for that particular pallet. This meticulous control over stock placement allows us to ensure precise allocation. Setting the height of the hanging sign and the length of the label to indicate the full height of an order enables us to determine when a pallet is fully picked. This standardization ensures uniformity across all picked pallets, eliminating the issue of varied heights we faced previously. The implementation of the new system has yielded substantial benefits, notably in the reduction of pallets dispatched to retailers. This optimization of truck loading not only minimizes the number of additional vehicles on the road but also translates to significant cost savings in distribution. The enhanced efficiency in logistics operations is a direct result of the innovative pick-by-line approach, showcasing a strategic and resourceful solution. In essence, the innovative sign system not only streamlines the logistical aspects of pallet picking and dispatch but also introduces a robust solution to longstanding challenges, contributing to overall operational excellence and cost-effectiveness.
