In 2019, Draper Tools turned to the intralogistics expert to relocate order picking and storage to its new site in North Baddesley, Hampshire, England. The aim was to make optimum use of the existing warehouse space, improve processes and reduce shipping times. A challenging task that could only be mastered through particularly close cooperation. "Throughout the entire project, the support from SSI Schaefer was exceptional. We had the feeling that we had a partner who not only worked with us, but also for us. They took the time to understand our complex business processes and helped us to optimize them," praises Matt Boschi, Operations Director at Draper Tools.

Handling of 11,000 stock keeping units

From an initial automation idea, SSI Schaefer and Draper Tools jointly developed a solution that is tailored to the tool wholesaler's warehouse layout, operations and diverse SKUs: 12 picking stations with pick-by-light flow racks for fast-moving items and shelving racks for slow-moving items, connected by bin conveyor technology across three levels. The semi-automatic overall system with 420 bins is designed according to the goods-to-person principle and enables efficient picking of up to 10,000 units per day.

Efficient order picking thanks to dynamic shelving system

As soon as an order is received, the orders are assigned to the containers, which are automatically started by the container denester. The bins are transported via the conveyor system to the pallet flow rack system (KDR) on the second floor, where they are loaded using pick-by-light. The KDR is ideal for small parts and, thanks to its robust roller rails, enables a smooth flow from the loading to the picking side. This significantly reduces the walking distances for employees, reduces the effort required for replenishment and speeds up picking.

Thanks to the compact storage in the KDR, the available space is also optimally utilized. In addition to the storage capacity, Draper Tools was also able to significantly increase the quality of its processes: the pick-by-light system virtually eliminates picking errors and significantly increases the picking speed.

Space-saving layout with expansion option

Handling large SKUs is also possible with the new semi-automated solution from SSI Schaefer. This is ensured by shelving racks, which can be flexibly adapted to different items and individually extended in height, depth and bay width, and wide span racks for bulky and heavy goods. The goods are picked into containers and transported to the second floor, where the entire process is repeated. For items that are too large for a container, there is a goods elevator. Conveyor technology connects all levels and workstations through to packing and goods issue on the first floor. The layout also saves space and gives Draper Tools every opportunity for adaptation and future growth.

Within just six months of commissioning the new warehouse solution, the most important goals were achieved. Matt Boschi, Operations Director at Draper Tools, comments: "We have seen a significant increase in picking and packing speed and are therefore able to supply our customers even faster."