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 distribution centre in Barnsley UK. Designed and installed by Japanese automation specialist, Daifuku, the system replaces what was formally a fully manual fulfilment process, transforming the business’s ability to satisfy 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 warehouse and logistics executive at Portwest explained: “Prior to our adoption of automation, our fulfilment process was entirely manual. In practice, this meant that we were able to complete no more than 30 boxes an hour. With our new automation system, we can now fulfil 300 picked boxes per hour. It was a very labour-intensive process. Moving to automation changed our whole operation.”
Automation has dramatically reduced the rate of mis-picks, therefore increasing service levels and customer satisfaction. This clearly demonstrates the positive impact automation can have on UK warehouse productivity.
Fully operational by late summer 2024, the new warehouse automation system at Portwest’s 15,000 sq m facility in Barnsley has more than doubled handling capacity, thereby enabling the business to meet anticipated demand for its products, which include high viz jackets, PPE kits and safety gloves.
Crucially, this has not seen any redundancies at the business, which from the outset wanted to prove that investment in automation could be used as a stepping stone to further growth, as well as more enriching roles for staff.
Automated high bay storage
Daifuku’s AS/RS comprises four high bay aisles serviced by four automated twin-fork Mini-Load cranes. High-density racking creates more than 76,000 unique locations within the upgraded facility. At more than 130 metres in length, the racking installation at Portwest is believed to be one of the longest installations of its kind in the UK.
A key feature of the system is its double-deep design and the ability of the cranes to store and retrieve two cases simultaneously. This enables greater storage capacity while providing high throughput, allowing greater warehouse efficiencies to be achieved.
Technology in operation
In simple terms, the Portwest operation works on the basis of a central in-feed of cartons, which are transported to appropriate zones (A, B or C) of the high-bay storage racking, depending on their demand profile. Daifuku worked closely with ULMA, its preferred European partner, to develop and install all of the in-feed transit conveyor systems.
Driven by a bespoke PLC, the conveyors interface with Invar’s software, which in turn communicates seamlessly with the client’s well-established M3 system.
Daifuku’s four cranes, the heart of the Mini Load system, are highly versatile and can handle, plastic containers, trays or in this case cardboard cartons. With nearly 60 years of experience and over 34,000 stackers cranes made, Daifuku’s AS/RSs are globally respected for their reliability and quality. Furthermore, with updates and development over the years, the cranes have been made lighter and employ smaller motors, reducing electricity consumption.
When called, cartons are delivered from the AS/RS facility into one of three lines:
- Lane one – these items replenish the adjoining Autostore, which serves pick and pack orders.
- Lane two and three satisfy bulk orders to customers, supplying cartons for onward despatch via next day delivery.
Russell Hutchinson, Daifuku UK sales manager, 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 will store it away until it is called upon.”
Automation for the nation
Portwest’s experience demonstrates that appropriate technology within the intralogistics function can transform the efficiency of manual handling processes. The business’s adoption of warehouse automation has drastically reduced mis-picks, doubled capacity and also created new roles at its site in South Yorkshire.
Clyde continued: “This exercise was never driven by a desire to cut manpower as it’s the people that make our business thrive. We’ve demonstrated that using automation in a considered way can bring operational efficiencies, while creating new, more enriching roles for people within the organisation.”
Portwest – Key automation highlights:
• The 76,000 storage locations are serviced by four Daifuku cranes, each operating its own Mini Load AS/RS system.
• Based on 80% utilisation, this system can handle 2,400 cartons on a dual cycle basis on any 12-hour day.”
• Each M Shuttle has been designed to handle box cartons. Utilising extendable side plates with movable pins at both ends, two cartons can be moved simultaneously from and to their desired location.
• Benefitting from extended arms, each shuttle also facilitates the use of double deep storage, further driving the productivity of the system.
• The AS/RS system is controlled by a bespoke WMS system, which integrates with Portwest’s incumbent Infor M3 ERP software.
• At 130m in length, the high bay racking at Portwest is believed to be one of the longest in the UK. It houses 76,000 locations.
