W&H Systems, Inc.

Application Profile

Bayside Distribution (RSU Tilted Tray Sorter)

W&H Systems, Inc. was chosen to provide a material handling and sortation system for Bayside Distribution’s new 130,000 square foot facility in West Sacramento, California. Bayside Distribution is the distributor for Tower Records and is also involved in mail order and third party distribution. The system, designed by W&H Systems, handles their Outbound Order Fulfillment and Returns Processing of entertainment products such as compact discs, audio cassettes, video tapes, software and hardcover/softcover books.

System Configuration

At the heart of the Bayside System are two independent RSU tilted tray sorting loops. Each loop is capable of sorting up to 12,000 units per hour for a total system capacity of 24,000 uph. The loops are arranged in a double-tier configuration that enables product to be sorted to 136 discharge points (68 packing stations). The system has four induct areas (two induct areas per loop). Each induct area consists of an automatic induction unit and two manual induction stations. Compact discs, audio cassettes, and video tapes are automatically inducted while software and books are manually inducted.

The Bayside System also contains a overhead Empty Carton System, that feeds the Packer Work Area with empty cartons, and a Full Carton Takeaway System, that transports the cartons through an automatic taping machine to a shipping carousel. The cartons are then pulled off the shipping carousel and palletized.

Outbound Order Fulfillment

Products destined for outbound shipments arrive at the RSU induction areas in pick carts, typically grouped by SKU within a wave. Each induction area has a display which indicates the current wave. If necessary, the order in which waves are inducted can be changed at the Sorter PC’s.

At each induction area, the operator sets the automatic induction unit for the product type and load the product in the orientation required for the barcode scanners. Operators can also choose to use one or both of the manual induction stations to hand induct “other” products onto available trays.Barcode scanners located above the sorters read the product’s Universal Product Code. Once identified, the sorter control system finds the SKU associated with the UPC and the orders that have an open quantity remaining within the current wave. The items are then sorted according to a “picket fence” algorithm. Jackpot chutes are utilized to remove all items that are not sorted because of full chute conditions or for items that do not have an order associated with them.

Returns Processing

Returned product that arrives at the distribution center has a transfer number that facilitates appropriate accounting credit. The display at each induction area indicates the expected transfers. The order of transfers can be changed at the Sorter PC.

Returns are sorted for either Return To Vendor or for Return To Stock. Templates govern the sort destinations within each mode. It is possible for multiple chutes to be allocated for a single vendor for Return To Vendor, or multiple SKU’s to be sorted to a single chute for Return To Stock. A round-robin algorithm is used.

The physical induction scheme is identical to Outbound Order Fulfillment.

Send mail to dbetman@whsystems.com with questions or comments about this web site.
        Copyright © 1998 W&H Systems Inc.
        Last modified: July 07, 2003

This site designed by:
Alpha Omega Software Corp.

Last Revised: 12- November - 2008