Dürkopp Fördertechnik, a leading European specialist in hanging garment storage and sortation systems, has installed a simple, flexible and low cost semi-automated system into Debenhams Regional Distribution Centre in Northampton. The system is centred around Dürkopp’s own Set Carrier, a simple plastic hanging frame that enables garments to be manually transported along an overhead tubular rail framework.
Operatives can control the direction of the set carrier and garments using simple railway-type points in the overhead rail to divert and convey garments to wherever they are required. The only powered systems are integral overhead conveyor sections taking trolleys up and down between floors.
The installation provides many of the benefits of a fully automated system while retaining a high level of simplicity and flexibility to adapt or adjust quickly to changing demands. As well as providing an economical and easily installed solution, the system’s straightforward design meant that Dürkopp’s team was able to complete the installation on the existing site in just 14 weeks from receiving the order, without disrupting Debenhams current operations.
Providing a practical first step into automated systems, Dürkopp’s set carrier uses only four components – an overhead rail, the carrier, switching points and vertical conveyor – all configured to meet individual client requirements. The 500mm long set carrier has integral rollers to provide smooth and easy manual transport along the rail, and can be coupled with other carriers for more productive handling.
The garment hanging bar includes a safety device to protect garments from falling and has an optional second, lower bar to double the carrying capacity when handling shorter items. As a further option, set carriers can hold an RFID transponder and/or a bar code label, to link data and stock information with a central WMS. Weighing only 500g, the carriers are light and easy for staff to handle.
Garments arrive from international suppliers to Northampton mainly in 20ft road container vehicles. Debenhams staff unload garments directly onto set carriers running on a rail extended inside the vehicle. In the goods-in buffer zone, garments are scanned and checked into the system, then taken by powered conveyor to the correct storage aisles located on the two upper floors, or directly to a ground floor cross-dock area ready for sorting to store.
On the upper floors, operators use the simple manual points in the rail track so that they can push the set carriers into the correct aisle for off-loading into storage. When store orders arrive via Debenhams WMS, operatives batch pick orders onto the set carriers, which are transported down to the ground floor dispatch zone by powered conveyor where garments are allocated to 112 store lanes.
Completed store orders are finally shipped through six goods out gates, each equipped with extendable set carrier rails for easy loading directly from the internal system.
Annette Sommer, Dürkopp Fördertechnik’s UK General Manager, explained why Debenhams selected the system. “The company’s management team were clear from the outset what they wanted to achieve, which included having a process that allowed them to retain full manual control at all times. The set carrier concept provided exactly what they were looking for, could be installed within budget and without causing any disruption to their business during a busy season.”
“While we have a strong track record across Europe of designing and installing fully automated systems for companies such as ASDA, Next, John Lewis, Marks and Spencer and Zara, we believe that the simplicity and low cost of the set carrier is likely to appeal to a lot more companies facing tight budgets over the next couple of years.”
Dürkopp Fördertechnik
Annette Sommer
Tel: 01455 299890
E: annette.sommer@duerkopp.com
www.duerkopp-web.de
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