(Commonwealth) _ When Samworth Brothers sought a new hanging sign for its chilled distribution site in Leicester, they opted to collaborate with inotec, a specialist in providing tailored warehouse labelling and line marking solutions. The outcome was an innovative ‘docket grab’ hanging sign that employs ball bearings to securely hold dockets. These versatile signs, available in single or double-sided configurations, are currently deployed in the pick-by-line area of Samworth’s Oak Meadow facility. The Oak Meadow site in Leicester, owned by Samworth Brothers, boasts a substantial storage capacity exceeding 10,000 pallets across chill, deep chill, and frozen storage. The facility, staffed by approximately 580 individuals, relies on the efforts of 160 warehouse operatives for order picking. Glyn Maude, General Manager of Samworth Brothers Supply Chain, elaborated on the necessity for the new sign: “As our business has experienced rapid growth in recent years, we needed to reconfigure how we fulfill orders in this warehouse. Originally, the entire area was equipped with racks, but a decision was made to dismantle part of the racking to create a pedestrian-only picking zone surrounded by barriers. “This redesign allowed us to present products directly to the pickers in that area instead of having them retrieve items from the racks. The pallet lanes extend towards the racking, and stock is delivered into the picking area from beneath the racking, courtesy of forklift trucks.
“I realized that hanging signs would be essential for the new area but couldn’t find anything suitable in the market. I had seen other companies using cut drainpipes as makeshift holders for labels and thought there had to be a better solution. I approached Steve Towler at inotec, whom I already knew from his assistance with line marking and signs for our marshalling lanes in Leicester. After providing him with the sign’s dimensions and functionality requirements, he developed the innovative ‘docket grab’ concept. A couple of mock-ups later, and we had our efficient and unique hanging sign solution.” In the designated pedestrian-only zone, our pickers utilize hand pallet trucks to collect pallets of stock and navigate the picking line of pallets. The process involves scanning the pallet label held in the hanging sign above each pallet, outlining the details of a retailer’s order. This method allows us to meticulously control the allocation of stock. The height and length parameters of the hanging sign and label are strategically set to indicate when a pallet is fully picked. Once the pallet reaches its full capacity, the picker can easily recognize that there is no more room for additional stock, ensuring uniformity across all pallets. Previously, our pallets had varying heights, but now they consistently come out at a standard height.
Our revised approach has led to a reduction in the number of pallets dispatched to retailers. It also enables us to maximize truck capacity, minimizing the need for additional vehicles on the road and subsequently reducing distribution costs for both us and our customers. The hanging sign system further enhances efficiency by keeping pallet labels elevated and secure, preventing issues such as falling off, getting stuck, or going missing. While our pick accuracy is already impressive at 99.98%, we are continuously striving to eliminate any margin for error. Although the pick-by-line system has been operational for a short time, I anticipate an improvement in picking accuracy. The signage work carried out by inotec has proven to be exceptional, and our collaboration has been seamless due to shared work ethic and perspectives. It’s a fantastic partnership, and I would rate them ten out of ten every time.”
