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TOP Picking Line TOP - Semi-Automatic Picking System > Maximum process flexibility > Picking magazines and > Open stacks or different boxes newspapers without any change or totes can be used at the TOP > Optimal packing quality picking line > Fast ROI > Outstanding productivity > Also used for other products > Permanent availability, no down as tobacco, lottery, photo and > Best ergonomics for your staff time drugstore articles Satisfied customers Graeme Underhill, significantly while maintaining effi- News Operations Director cient distribution costs. WH Smith, UK: TWI has been an excellent business partner to us and we have complete „We have been operating TWI confidence in their ability to deliver TOP packing and HIT tracking world class systems - so much systems throughout our estate of so that we have been developing 52 distribution centres since 1998. further systems with them to handle These systems have enabled us magazine unsolds and newspaper to improve customer service levels packing.” 1 Advantages to convince you Today TOP is the best packing > The entire system has a modular next indicator light appears and the strategy world-wide. The system and sturdy construction. ‘Plug in’ counting continues without time represents high-technology for subassemblies provide a high re- losses. the distribution of magazines and dundancy. The transport method is newspapers. quiet and very economic. > The delivery note is printed on-line at the end of the picking process. This Optimised transport techniques and guarantees that the content of the visualisation (pick and place to light) note is exactly correct. As an option are integrated into one system. the note is added automatically to the bundle by means of a pressured The following features make TOP the air driven delivery note dispenser. fastest picking line world-wide and provide the best packing quality: > An intelligent scales system may be integrated for quality assurance. > Open stacks of press ware move on a buffered picking line, > The actual use of the picking which combines the advantages line varies. Packing magazines, the of a conveyor belt and a buffered whole line is used; bundles moving roller conveyor. TOP stands for along all displays towards one end transportation without transport tool > Bundles are generated in the into a high speed strapping machine. (German: Transport ohne Palette). packing zone where their first title Packing newspapers, the picking This enables the essential ‘birth of is to be picked. Hence, the picking line is driven in two directions. Then new packages’ at any point along the line’s transport load is relieved of strapping machines are used at both picking line. This particular transport unused empty bundles. Those are ends. technique is the reason for our usually necessary in conveyor belt overwhelming productivity. systems to constitute the proper > The recording of tote bar codes route sequence. during the picking provides data > Drives free of collisions and jerks for an associated track and trace are moving the open stacks quickly > Intelligent position control with system. and ergonomically well arranged to target indicators show the picking the picking person. Bundles never person where to place a respective > Further automation provided by collide and stop exactly where copies amount of copies. When the action TWI will save staff and improve the must be added. is acknowledged, immediately the total shipping quality. TOP-Displays bundle on the transport. There the with our new „blue light strategy“ in picked material must be added. the upper shelf. Independent picking When the acknowledge button is hit, avoids waiting time and accelerates immediately the content of the next the picking process itself. The picking procedure is controlled bundle appears on the LEDs and To add customer specific information, by an electronic display. The display the person starts picking for the next like returns calls, invoices etc. is situated directly in front of the retailer bundle. we developed a special display title. Large LED figures indicate Picking and adding products to to indicate clearly a full customer how many copies are to be picked. bundles which are still positioned in number when the bundle passes in Green LEDs point to the respective the upstream picking zone is possible front of the picker. 2 Best ergonomics, friendly maintenance, fast installation The picking line’s basic height The anti glare illumination of the conception is the intelligent man- meets ergonomic demands. Arms entire machine is a further contri- machine interaction. It combines remain relaxed and backs straight, bution to ergonomics. the computers strategic and com- when stacks are placed onto the putational capacities with the irre- picking line. This improved design is At convenient working speed, the placeable manual capabilities of combined with an additional second system achieves optimal picking man. floor which is convenient to reach. rates. An essential feature of the TOP allows packing titles of any size simultaneously, from paperbacks to the biggest newspapers. The TOP may run 24 hours a day and achieves really high productivity. Picking lines should never break down for long. In case this happens any module can be easily replaced without tools in 5 minutes maximum by semiskilled workers. We deliver the system with an adequate set of spare parts. Designed in aluminium the whole system is based on a sturdy frame especially for the tough warehouse use. The TOP-system is assembled out of 2 meter long sections, tested at TWI and installed to a whole commission line at the final place. The installation just takes a few hours and if you wish we can do it during the weekend. So your usual working processes are not interrupted. The transport mechanism On a roller conveyor, the bundles are variable and do not depend on move at a speed of 0,4 m/s. The mechanical components. bundle’s weight is carried by many Intelligent sensors guarantee fast small rollers, while the in-between motion, avoid collision and buffer the toothed conveyor belt rises and stacks, which are smoothly accele- lowers on computer command. rated, in order not to risk tipping. This movement is controlled by a If a stack does tip, the respective great number of sensors. Every transport stops automatically. When The US-patented TOP transport mechanism is controllable segment has a length the stack is reorganised, the transport based upon a central toothed conveyor belt which is of 0,25 m. Actual counting zones will be restarted. controlled in sectors each 250 mm long. 3 Why is TOP so fast? – „Birth of new packages“ PRODUCTION DELIVERY SEQUENCE A special feature of the transport the first product is collected. E.g. if allows generating new bundles at any a bundle gets only titles which are position of the picking line. Therefore, positioned in the last picking zone, the picking line can be started with the bundle will be generated at few bundles at the far end. Spacing the end of the conveyor. Between for future bundles or delivery notes two existing stacks an open space are not required between the first emerges, marked by the two green packages. This increases the pro- lights. This is possible due to the ductivity dramatically. sophisticated conveyor control. At this open place a new bundle of TOP with „birth of new packages“: newspapers or magazines is put With our TOP system a bundle is down on the transportation belt. generated in the picking zone where 4 First class parcels – Satisfied retailers any customer defined layout as far as text, price information etc. is concerned. We realise your specific layout wishes. As printing technology we use the standard and convenient matrix printers or laser technology from Tally or Kyocera. For both types we offer automatic delivery note dispensers with a vacuum cup. In case you use totes we integrate a tote labelling system at the end of our tie-line. We realised gluing labels that are fixed on the bundles or paper labels that are slipped into a little window at the rim of the tote. Sample delivery note with a controlled output for special situations like credit data, redeliveries etc. It‘s the first delivery note of a consignment of 3 parcels. As soon as a bundle has received directly added to the right bundle, its last title, the delivery notes are automatically by a dispenser. printed on-line by two high-speed printers integrated at the end of the Delivery notes will automatically be picking line if you wish. The up-to- corrected to reflect missing titles. date delivery note is printed and Delivery notes may be printed with Delivery note dispenser HIT – Interfaces to track & trace and returns processing It is understood that the TOP system which may be needed during the returns processing machine can sends all data back to the host. This track & trace process. The HIT immediately identify the retailer using is why we integrated a sophisticated track & trace computer retrieves via the bar code on that tote. A safe and up-load interface into our data a docking station its information. fast customer change is realised with base. During the picking process The docking process may be done our approach. You don’t need returns all changes are carefully monitored. through a LAN from a remote slips any more and you can realise On-line or after the production result satellite hub station. optimal service for your retailers. files are up-loaded to keep the accountant in line with the delivery We also connect that data base to The transport manager can see process. the returns processing machines. at any time which customer is in Internally we rely on ORACLE® So when a tote filled with returns possession of which tote. This is database. That database also stores is collected and is opened in the a perfect integrated tote assets those data from the picking process returns department, the TWI 200 management. 5 Software highlights of copies to be picked. You can use the drag&drop system to realise your allocation strategy much more faster and easier. Picking areas are variable and inde- pendent of the mechanical set up. Picking areas can be wide or small depending on the amount of copies to be picked. In addition to the maximum height and weight and the tolerances, it is also possible to set up a minimum weight and height to suppress very small final parcels to customers who get more than one parcel. Route planning Planning the routes: The graphics of the “route planning” give you at once the accurate over- TWI implements a customer specific Title management: view of the utilisation of all routes. connection to the data centre which The flexible title management en- enables a simple management of all ables that all titles, independent of A graphical overview over all the picking procedures. which kind of data source they come route data shows the amount of from, can be disposed in different bundles, the distance and duration No matter if the picking will start dispatches. of the different routes to help you to immediately, is already going on or reschedule and optimise all routes is finished and the data has been Also titles can be sorted into an extra more efficiently. sent back to the data processing dispatch for small drawn titles, late centre. coming titles or redeliveries. Additionally with this instrument all the data of the retailers who are on The interface to the data centre can Which titles are picked at which time, vacation right now or who are clos- be managed on-line or off-line, also during the day or during the night, ing their shops can be controlled and input and output of data can be man- may be decided at the time the titles modified. aged differently. arrive. Naturally it is possible to manage all When working on-line all available Before, during or after the dispatch the goods of these retailers: Which orders will be imported automati- exotic or late titles can be picked by titles have to be kept, which titles cally, therefore all orders will be our HIT-Handy or can be picked as have to be delivered for example to handled immediately. In that case a separate dispatch or can be trans- retailers in the neighbourhood. also the output of data is connected ferred to a future dispatch. “on-line”, all already done orders Statistics: will be reported to the data centre Title allocation: All sorts of data interpretation is pos- at once. A graphical display will show the sible and all analysis can be trans- most efficient allocation of titles to mitted into most common available displays according to the amount MS-products like Excel etc. 6 TOP options HIT-Handy New picking strategies Our “HIT-Handy”, a small hand- During day time inside the held computer, features a bar code warehouse the same HIT-Handy will reader, a GPS Navigation system, do a lot of additional jobs: It is used one control button and a speaker e.g. for the picking of small drawn able to talk in many languages. All titles in advance of the main picking included in a tiny housing with a process. rechargeable battery. In connection with TOP the HIT- During distribution at night it leads Handy shows its potential: more the drivers to each retailer and titles than displays in one dispatch. HIT-Handy with GPS - track & trace, scanner, controls all their activities with the It can be used during the main de- speaker and interface button in its docking station. HIT software. livery to pick full bundles or rede- Additional functions of the HIT-Handy are explained liveries to speed up the picking line. in the HIT brochure. Flexbox Stabilising goods with “add-ons” Magazines containing add-ons or Flexbox transports the stack as gadgets are difficult to manage on far as the strapping machine and the picking line because of slippery uncoils itself automatically from the plastic foil and uneven surfaces. stack just before the strapping. Our answer to this issue is called The empty Flexbox is returned Flexbox, a lightweight loading tray automatically to the picker to be to stabilise slippery stacks from all used again. four sides moving on the TOP line. Flexbox on the TOP picking line HIT-Rolli or Display-Shelf behind the TOP picker - more titles than displays Small drawn titles can be stored behind the back of the TOP pickers in a mobile shelf. Instead of setting up small drawn titles on the picking line a person collects those titles with the HIT Handy or from the shelf with the displays and then add the „part bundle” while the high drawn titles Display-Shelf HIT-Rolli are picked on the TOP line. 7 The useful accessories for your system but increase the quality of the process. Our software does not need any reference values for the objects weights and therefore it works with- out any preparation efforts! All bundle weights are stored auto- matically during production itself. The software evaluates all data after the end of the production. After a few minutes the reference weights of all titles are recalculated. The wrong bundles are marked in a list and a forecast for the presumably Carriages for high volume titles wrong titles is generated. The wrong View at the replenish side of a TOP picking line bundles can easily be corrected with minimum effort. To store the stacks securely and moved around freely. They are a have them available immediately very efficient buffer system. > Private scales system per picker when you need them, we suggest To increase the picking quality to put the copies on carriages and All these is meant to do part of the especially for untrained pickers mobile storages. refilling “off-line”, in order to need we developed the “private scales less people to do that job while the system”. A movable tablet works Basically the TOP picking line real picking is done. as a scales with full screen display. comes with a one meter deep In case of discrepancies, a forecast aluminium rack. Some of our > Quality check is calculated and the title that customers prefer conventional As quality assurance mechanism presumably is wrong is highlighted. roller storage up to 2 m depth per some wholesalers control the This helps to correct the mistake channel. We recommend to use an magazine bundles which are ready directly. If the picker hits the touch elaborated type of rack: for delivery with a scales system. screen, the list of all order lines is This gives a reduction of picking displayed. > “Carriages” are fixed movable errors, checks the own pickers and in a rail mounted at the rear of the decreases wrong claims, because lower floor of the 1 m deep roller all customers know that there is a storage. This rolling prolongation scales for checking. In this way the of stock is just hooked in. The width quality of the delivery is increased. of such a “Carriage” corresponds to However, you must weigh all the the width of a stock channel. titles before the actual production starts. > A “Mobile Storage” is installed in front of TOP, where the picking > Final inspection scales system persons are posted to supply the The TOP-intelligent scales solves high-edited titles directly. They are the problems in another way. The basically designed like “Carriages”, aim is to get rid off the mentioned just on four wheels and can be disadvantage of weighing all titles, Private scales display 8 General highlights > All press-goods from paperbacks > Customer texts provide special tries to minimise the work and the to daily newspapers can be packed informations for separate retailers overall transport. That means the at the same time. or groups of customers or both. computer calculates bundles, which are packed in a minimum of zones. > You can print a final delivery note > You can print all full bundle So you get a high degree of parallel at the end of the picking line and information at the same time on the work, highest efficiency of packing have it pushed automatically onto delivery note and a full bundle list and the best use of the transport the bundle. grouped by routes. buffer mechanism. > Outstanding quality of the cus- > For the late deliveries you can > Adjustment to actual demand: tomer’s bundles and outstanding print pack–lists and delivery notes, rearrange routes and drop se- productivity from the pickers. which are packed by the driver or quences; deal one urgent route in the warehouse. Alternatively first; pack special customers im- > Minimal bundle transport length you can transmit the data for these mediately. by “birth of new packages” at its copies to the computer centre or first place to be used is saving add them to the next production. > Status control indicates infor- space and time. Variable position to mation about each parcel, retailer generate new bundles at any place > All direct deliveries can be or route. Percentage of workload of the picking line will prevent early printed on special lists, grouped still to produce is also available blocking of the pickers. for different routes and for further and the estimated finish time. A processing. journal shows a time stamp of each > Missing titles are directly re- important milestone (start, bundle gistered and marked in the print- > Production in two opposite di- ready, reset, missing amounts, etc.). outs; the retailer knows why and rections allows to process urgent how many titles are missing. The routes first. Sharing titles or routes > TOP writes the process produc- wholesaler’s accounts department allows parallel production. Several tion data into an internal database, knows just after the end of the pickers may pack the same title. where access is allowed for many production which customers got This results in really high output different evaluations. which titles. quantities for the picking line. > From the hardware side the > As reaction to the shortages > The automatic mapping assistant double amount of sensors and you can decide between “credited” of the TOP-system allocates the actors are installed to have a (price not taken into consideration), titles automatically to the desired maximised assurance against “later delivery”, “compensation”, number of picking zones. Knowing breakdowns. “separate delivery” or else. the exact amount of copies per titles, based on different methods > All segments of the electronic > If you get too few or too many they are allocated close to the LED displays are permanently copies of a title you can adapt the final stopping point or upstream supervised, failures that cause supply of each customer. There are in a zone. Also the frequency of wrong delivery numbers are special algorithms to deploy the contacts is considered. The zones impossible. reductions fair (percentage, a fix are averaged equally with respect amount from each pack, manual to workload. > The most important thing is adaptation). the “five-minutes-rule”. Here, you > The internal pack separation have the guarantee, that you can > Objects not available can be algorithm uses the final allocation fix every failure in a short time by deleted and undeleted in the pro- of objects on the TOP-system to yourself and your delivery never is duction all the time. generate handy parcels. Further it endangered. 9 Typical Data of a magazine dispatch as a list Date Copies Bundles Title Persons Manhours Contacts Cp/Pick Bun/m Productivity % over TOP-Warranty 11/1/04 68023 1921 167 4 23.7 20591 3.30 5.4 2866 56.2 11/2/04 78834 1657 50 2 14.6 15085 5.23 3.8 5399 136.7 11/2/04 93764 1976 68 3 19.7 19905 4.71 5.0 4770 120.7 11/3/04 59867 1902 49 2 11.1 12340 4.85 5.7 5378 145.1 11/4/04 60276 2293 61 2 14.7 11966 5.04 5.2 4102 83.4 11/4/04 44482 1794 70 2 10.7 10147 4.38 5.6 4150 99.0 11/5/04 67161 1473 28 3 11.4 9499 7.07 6.5 5917 118.4 11/7/04 22826 1122 24 2 6.5 5666 4.03 5.7 3490 74.2 11/8/04 50875 1351 164 4 19.8 17601 2.89 4.6 2572 47.9 11/9/04 97810 2169 67 3 22.4 18082 5.41 4.8 4364 87.8 11/9/04 119848 2455 76 3 24.6 23393 5.12 5.0 4862 115.4 11/10/04 100052 2563 72 3 20.9 16964 5.90 6.1 4787 96.4 11/11/04 51218 1610 82 3 12.7 11113 4.61 6.3 4040 89.0 11/12/04 52079 1318 24 2 6.5 5870 8.87 6.8 8052 157.5 December : : : : : : : : : : January : : : : : : : : : : February : : : : : : : : : : 3/18/05 36467 1135 26 2 5.4 6291 5.80 7.0 6727 178.7 3/20/05 39594 1609 33 2 7.3 9007 4.40 7.4 5449 160.9 3/21/05 82062 1905 65 3 16.7 16906 4.85 5.7 4915 123.9 3/22/05 74514 1621 75 3 15.8 15736 4.74 5.1 4710 117.4 3/22/05 88067 2280 69 3 18.6 19080 4.62 6.1 4722 120.7 3/23/05 56087 2053 52 2 11.5 11152 5.03 5.9 4866 117.7 3/23/05 44491 1700 61 2 8.4 9223 4.82 6.7 5269 140.8 3/24/05 49197 1188 140 4 17.3 16892 2.91 4.6 2837 62.7 3/25/05 54182 1387 52 3 9.6 9297 5.83 7.2 5655 133.6 3/29/05 96597 1912 65 3 19.7 19338 5.00 4.8 4899 120.0 3/29/05 78550 2021 66 3 16.1 14313 5.49 6.3 4866 107.8 3/30/05 65563 1693 94 3 13.6 13749 4.77 6.2 4823 121.8 3/31/05 68150 2335 115 3 20 18084 3.77 5.8 3409 75.5 Average 64,501 1,769 71 13,821 4.67 4,377 103.5 Typical Data of a night (newspaper) dispatch as a list Date Copies Bundles Title Persons Manhours Contacts Cp/Pick Bun/m Productivity % over TOP-Warranty 5/2/00 45202 947 59 4 7.2 5111 8.80 8.8 6278 101.0 5/3/00 41900 883 61 5 7.6 5025 8.30 9.7 5513 83.6 5/4/00 51985 1158 66 6 11.1 6249 8.30 10.0 4683 56.2 5/5/00 41594 928 61 4 5.6 4181 9.90 11.0 7375 118.0 5/8/00 41920 883 50 5 6.4 4359 9.60 11.0 6499 96.9 5/9/00 41404 870 56 5 7.0 4313 9.60 10.0 5873 78.2 5/10/00 40594 870 57 5 7.8 4633 8.80 9.3 5204 67.8 5/11/00 51338 1148 66 6 11.8 6110 8.40 9.7 4343 43.9 5/12/00 41581 912 58 5 7.4 4795 8.70 10.0 5619 82.4 5/13/00 45481 1133 48 4 7.2 4148 11.00 10.0 6317 74.8 5/15/00 42516 890 50 4 7.2 4523 9.40 8.2 5905 81.7 5/16/00 41711 869 58 4 9.0 4294 9.70 6.5 4655 40.1 : : : : : : : : : : : 5/16/01 45762 1081 45 5 7.3 5117 8.90 12.0 6269 99.4 6/18/01 41076 866 48 5 5.7 4041 10.00 13.0 7270 112.0 6/19/01 39313 832 54 5 5.7 3792 10.00 12.0 6958 100.0 6/20/01 40441 850 54 5 6.1 4526 8.90 12.0 6630 111.0 6/21/01 45549 971 59 5 7.1 4841 9.40 11.0 6415 97.3 6/22/01 40165 898 52 4 4.8 4492 8.90 12.0 8299 164.0 6/23/01 45825 1098 45 5 7.0 5182 8.80 13.0 6500 108.0 6/25/01 40418 864 49 5 5.8 3991 10.00 12.0 6969 104.0 6/26/01 40219 842 52 5 6.0 4092 9.80 12.0 6759 102.0 6/27/01 41219 875 55 5 7.1 4658 8.80 10.0 5765 84.6 6/28/01 45578 963 59 5 7.4 4878 9.30 11.0 6201 91.6 Average 9.40 6,097 87.3 10 Typical data of a magazine dispatch as a diagram Increase of productivity Customers data of the year 2001 compared to the data of the results from customer year 2005 show an increase of productivity from 4022 copies per average 4022 / 5,2 man-hour to 4377 copies per man-hour although the copies per pick decreased from 5,2 to 4,67 copies/pick. twi warranty productivity in copies/man-hour Diagram of the year 2001 9500 9000 8500 8000 7500 Produktivität (Exemplare/Mannstd.) 7000 6500 6000 5500 5000 4500 results from customer 4000 average 4377 / 4,67 3500 3000 2500 2000 twi warranty 1500 1000 500 0 Diagram of the year 2005 0 1 2 3 4 5 6 7 8 9 10 copies/pick Dichte (Exemplare/Kontakte) Typical data of a night (newspaper) dispatch as a diagram productivity in copies/man-hour results from customer average 6097 / 9,4 twi warranty copies/pick Please note: Each dot represents one dispatch. 11 References Since 1993 we implemented over 110 TOP-Systems to over 40 satisfied wholesalers. 58 Systems in 37 houses in Germany 25 Systems in 23 houses in the United Kingdom 28 Systems in 12 houses in Denmark, France, Switzerland, Luxembourg, Australia, Russia and in the USA Worldwide working All our TOP-Systems, 2000 metres long overall, produced up to now customer bundles with more than 11.000.000.000 copies and a load of over 3,1 millions tons. The average productivity of all cus- tomers is 2.660 Copies / Man hour with 3,5 Copies / Pick. Within 580 years of use not one dis- red = TOP tribution had been cancelled. green = TWI 200 / TWI 300 yellow = TOP + TWI or HIT This superb availability results from extreme design redundancy of all important components and our maintenance concept called “5- minutes-rule”. 12 Layouts of some TOP-systems The organisation of a TOP machine is very flexible: Best seller: 18 metres, 136 displays, laser- and label printer, roller rack 1 metre in depth, carriages, tote picking and data up-load to HIT – Track & Trace and SAP host. Best flexibility for larger customers: twice 20 metres, printer in the forward and backwards direction. Back to Back – arrangement for optimal use of space. A small machine for special uses: For extra distributions like trading cards etc. where conventional systems cause major problems TOP shows best efficiency and high productivity. Our largest machine: Ready for more than 200 titles in one distribution. If convenient, split the system into two distributions, one in the forward and one in the backwards direction. Roller racks up to 3,3 metres in depth. Our fastest machine: 24 metres in length, printers and delivery note pushers on both sides. Carriages and mobile storages are available on both sides of the track. Result: Magazine distributions with more than 4300 copies / man hour. Basic system without printing functionality: Delivery notes printed elsewhere are just added at the end of the machine. Fast picking and superb transport features are available. Further the famous “birth of new packages” results in highest overall transport speed. 13 Fast and error-free picking with TOP packing line Semi-automatic picking line with high flexibility, great packing quality, outstand- ing productivity. For magazines and newspaper, but also for tobacco - the solu- tion for all packing jobs. HIT – Highly integrated transport for your logistic system The bridge between distribution, logistic and returns department. Track and Trace of your parcels and trucks with GPS technology. TWI holds an European and US patent for the tracking of press articles. No lack of time for the driver, no installation at the retailers, all data ready from day No.1! twi Industrieberatung The TWI 200 express - returns processing GmbH & Co. KG TWI 200 express - crediting and sorting of returns with the highest quality. Industriestraße 6 Manual bar code returns system with automatic sorting outlets - high productiv- 76189 Karlsruhe ity and a secure process. Productivity of 2000+ copies/hour excelled in reality! Germany Tobacco packing - outstanding achievements in quality and productivity T (+49)(0)721 950770 Control over the whole consignment: from the goods in to the retailer or the vend- F (+49)(0)721 574832 ing machine. The slow-moving items are picked using a secure, audio-based www.twi-germany.com hand-held computer, our HIT-Handy. The fast-moving items are picked on the firstname.lastname@example.org display-based TOP system with an automatic transport of the parcels.
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