Conveyors: Optimizing the End of the Line
Transport is only part of the equation
Conveyors are primarily a transport mechanism within a facility: they move products from point A to point B to point C. Value is added at all points along the way. They’re the most efficient way to do that, even if that’s the only task they have. However, that’s rarely the only way they’re used. They’re loaded at point A, then transport the load to points of value down the line. Processes are is executed at point B, and something is finalized at point C — at the end of the line. Let’s dive into the ways you can drive value at the end of the line.
Delivering orders from within a system to a shipping area is a core conveyor function, but conveyors do more than that: they connect and integrate functions within an operation. They help unify order picking, packing, assembly and shipping.
Almost every distribution center operates under similar sequences
- Orders are inducted onto conveyor system.
- Conveyor transports the orders to areas where the order is picked.
- Picked orders are delivered to packing or quality control.
- Finalized, packed orders are delivered to trucks.
What are the value points in this sequence?
Picking & assembly
In a pick to conveyor operation, orders move along a conveyor line. When executed correctly, this helps process them from storage areas in the fastest, most efficient way possible. A typical pick & pass order fulfillment system inducts orders at the most efficient spot on the conveyor system and then transports it to the next logical position. That position can be to add more SKUs to the order, or on to a packing or quality control function.
That order can be a single carton that may be part of a larger order, a tote that is filled with each-pick SKUs, a pallet that is built along the way, or other types of storage/order media.
It’s not much different for assembly operations. The assembly line process is over a century old and remains the same. The manufactured item moves along a conveyor line and is assembled, welded, configured or otherwise modified by various functions — people or robots.
Read more: Picking to Cartons vs. Picking to Totes
Packing & quality control
Once the product is finished with its initial work, it moves to packing and/or qualify control functions. Many companies combine these functions into the same area, while others have distinctive groups who execute the process.
For instance, one of our customers uses an algorithm based on item counts, weights and sizes to divert orders if they do not meet the criteria. Orders that are within the correct range for weight, size and count continue on to the next function.
Remember that the conveyor can be a critical part of a well-designed packing system. Accumulation systems buffer orders while the packing group is overwhelmed. Using sensors, diverts and stops can automate workflow to the least-busy workstation. Gravity sections and ball transfers can function as workstation ergonomic enhancements. The key thing to understand is that conveyors can be purpose-designed to fit the projected workflow and load.
The design and integration of packing stations
Packing station design should be carefully considered. The questions you should consider are:
- Ergonomics: how will workers interact with all elements. The order, the workstations, the conveyors, storage and production equipment.
- Takeaway: once orders are packed, how will they travel from stations to the next point?
- Automation: what part of the packing process can be automated with good ROI?
- Space: how much space does the packing area occupy. Will that be enough for future growth?
- Capacity: What prevents packing from becoming a bottleneck?
Packaging
Packaging is usually a post-packing function, but that isn’t always the case.
When totes are picked, then conveyed to packing, they’re inserted into cartons, which can then undergo a number of packaging functions. Automated carton building systems can create exactly the right sized carton for the order, which minimizes dimensional shipping costs. That’s typically considered a packaging function, but can be executed further up line, particularly in pick-to-carton systems.
Most all packaging automation results in direct labor reductions that otherwise would occupy lower value positions. Things like void fill, label application, banding and printing are best done by machine wherever possible, freeing workers for higher value tasks.
End of line packaging options
- Void filling:Â Automated void filler machines are ideal for conveyor end-of-line integration. Modern systems are fast, reliable and occupy little space.
- Printing and labeling: this is an ideal way to maximize efficiency near the end of the conveyor system. Print and apply systems are a reliable and widely available technology that marry well to most any conveyor system. Printing systems tend to occupy minimal space and can handle higher order volumes due to their speed.
- Weighing: checkweighers can confirm package weights without diverting human labor. It’s a highly efficient way to ready the order for shipment.
- Banding, taping and strapping machinery: Banding loads is one of most tedious jobs around, and it’s slow. With the right sequence design, you can send all packages through the same line to be printed, filled, wrapped, or banded without human involvement.
- Carton sealing machines remove the labor and hassle of tape guns and manual work. Your packers can focus on counting, stuffing and handling orders rather than taping them.
Palletizing
Palletizing and conveyors tend to be paired in almost all automated or semi-automated distribution applications. The conventional method–people removing boxes and stacking them to form pallets on the floor–is one of the worst ways to execute a difficult, stressful and backbreaking task. There are many applications for marrying conveyors to automated or semi-automated palletizing systems that reduce injuries, increase speed and result in more uniform, stable stacked pallets.Conveyors can both feed and discharge loads from these palletizing systems and are an ideal mechanism to reduce the labor commitment to that process.
Read more: Targeted Warehouse Automation: Manual Pallet Handling
Truck loading & cubing
The final conveyor integration point is often feeding a truck, with either pallets, packages or a mix. This is an area of growing concern for manufacturers and distribution centers, as it’s a lower value, un-ergonomic task that requires significant labor and burns too much time. You can use conveyors to deliver deep into waiting trailers, which reduces the amount of time it takes to cube the truck out and send it on its way.
Videos: extendable conveyor systems
There are many types of conveyors that can extend into trailers, giving you options no matter the load or application. Two conveyors, the drive out belt, and flexible power roller system, are displayed below. See Extendable conveyors for more information.
Download Cisco-Eagle’s guide to conveyors & systems
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Scott Stone is Cisco-Eagle's Vice President of Marketing with more than thirty years of experience in material handling, warehousing and industrial operations. His work is published in multiple industry journals an websites on a variety of warehousing topics. He writes about automation, warehousing, safety, manufacturing and other areas of concern for industrial operations and those who operate them.