The scalable flat-pack picking solution from SSI Schaefer picks heavy and bulky items fully automatically and efficiently using gantry robots. With the automated and turnkey system solution from a single source, SSI Schaefer supports efficient pallet assembly for online furniture retail and store delivery. The concept can also be transferred to other industries that work with large-volume and heavy goods, such as wood and metal blanks, fence elements or windows. The picking module with smart gantry robots enables efficient handling of heterogeneous article ranges, relieves employees of less ergonomic tasks and ensures a constant flow of goods. The highly innovative flat-pack picking solution can process both orders for delivery to stationary retailers and online orders triggered by the end customer in parallel, quickly, reliably and efficiently.

Compared to tunnel picking, which requires walking routes and separate replenishment areas, this automated solution also takes up around 50 percent less space. Operators benefit from reduced logistics costs per order and also save on fixed costs, meaning that the investment pays for itself quickly. SSI Schaefer supplies this customized system solution from a single source. All components - from hardware to software - are manufactured in-house and are synchronized with each other. Both gantry robots and grippers were developed and integrated by RO-BER, a Schäfer Group company. This ensures maximum quality, sustainability and investment security. The flat-pack picking solution has a modular design, is flexibly scalable and can be adapted at any time to the growing business volumes forecast for the industry in the e-commerce sector, even in post-corona times.

With Flat Pack Picking, an integrated solution is now available for the first time that can be used to master the specific requirements of the furniture trade within a single system. The solution is the result of an initiative by the SSI Schaefer specialists in the "Retail & Wholesale" division, which was brought to market maturity in cooperation with a multinational furniture group. Innovative gantry robots take over the picking of heavy and bulky items so that staff can focus on handling lighter items or be entrusted with other tasks in the warehouse. The flat-pack picking module, which comprises hardware and software and is supplied by SSI Schaefer from a single source, is designed for high performance, is flexibly scalable and can be installed in both new and existing warehouses on a small footprint to save space.

Another special feature is the efficient palletizing: with the help of intelligent algorithms, the system automatically generates packing patterns based on the various SKU specifics so that the stability of the load on the order pallets is optimized and the volume is reduced. Using simulation, it was possible to demonstrate that up to 290 picks can be made in one hour when using four gantry robots with a corresponding order structure. As replenishment and picking are fully automated, a consistently high performance is achieved. Flat pack picking relieves staff of monotonous work, which in turn increases motivation.

This article appeared in issue 6/23

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