Resulting from strong growth in online sales Holland and Barrett (previously De Tuinen) needed a separate operation to process these orders. Holland & Barrett contracted Pcdata to implement a fast and scalable order pick system based on Pick to Light and PickCarts. The result: higher productivity, fewer errors, faster turnaround times and a far less chaotic workplace.
Holland and Barrett is expanding in the BENELUX. In 2003 the British based food and supplements giant acquired Dutch based De Tuinen and in 2013 they added Belgian Health Chain Essenza. “Over the past few years, we have consistently opened 20 to 25 new stores each year,” says logistics manager Vincent Schippers of Holland & Barrett. Holland & Barrett also has big growth plans for online sales and their efforts are paying off. Online sales have grown tremendously since the introduction of the web-shop. “A few years ago we established a separate e-commerce department. Having a department dedicated to stimulating on-line sales has had a big impact”, said Schippers. Holland and Barrett also plan to provide an expanded offering, with “web-only” products in the online shop in addition to the entire store assortment.
Walking distances
Strong growth online forced Holland & Barrett to review order handling in their warehouse operations.
Historically online orders were collected, packed and made ready for shipment in the Distribution center in Beverwijk.
This DC supplied all Benelux shops.
The resulting process, where stores and on-line sales were handled at the same time, was disrupting store operations and creating turmoil at the warehouse shop floor. Besides, collecting small Internet orders in what was a conventional pallet warehouse resulted in large walking distances and long lead times.
The decision therefore was made to set up a separate internet operation in addition to the existing retail store, resulting in a 30,000 sq ft expansion of the Beverwijk DC, including a mezzanine area of 17,000 sq ft. Pcdata was responsible for the entire project.
Eight zones for fast mover SKUs
The e-commerce operation is largely located on the mezzanine floor, where a nine-zone picking system was installed.
Eight of these zones are set up in 2 rows with flow racks, designed for fast movers. A total of 1,500 pick locations installed with pick to light-displays.
The ninth zone consists of shelving with space for another 8100 slow movers.
A conveyor connects the eight flow rack areas with the ninth zone. In this 9th zone the totes, filled with the fast mover SKUs are placed on pick carts, to collect missing – slower moving – products.
Process flow fast mover area – Pick-to-Light
The process starts when pre-labelled shipping boxes (totes) are placed on the conveyor. The barcode on the tote is scanned, linking the box to the associated order. The conveyor transports the shipping boxes to the correct zones, where it is kicked out for picking.
Each zone display will show the number of products the picker needs to pick for that zone. At the same time pick-to-light displays light up, showing how many pieces need to be picked at that location.
Slow mover process – PickCart 20 orders at the same time.
Each of Pcdata’s five Pick Carts have the capacity to hold 20 totes. Scanning the barcode the tote links that box to one of the locations on the cart. Each location is equipped with a put to light displays. Once the Pick Cart is loaded, the touchscreen tablet mounted on the cart informs the operator which location to go to.
As the rounds along the racking is completed, the operator puts the totes on the conveyor that transports them to six packing tables on the ground floor. A quick content check by the packing employee verifies the accuracy. A delivery note and any necessary folders are added and the box is closed. Final action is to attach the shipping label.
Pcdata as System Integrator
Pcdata provided the entire solution, from pick to light system and pick carts, the software controlling the conveyors, the conveyors themselves, to flow racks and shelving. As main contractor Pcdata was responsible to plan the entire project including integrating all the separate systems.
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