BS Handling Systems has designed and installed a complete materials handling and storage solution at 3PL Noatum Logistics’ 378,000 sq. ft. UK distribution centre (DC) in Medway, Kent.
The £3.5 million turnkey package includes racking for flat-pack, a goods-in monorail system for hanging garments (GOH) with elevators up through four mezzanine floors along with tote and goods-in conveyors with booms for flat-pack boxes.
There is pick-to-light on the ground floor for eCommerce fulfilment and a goods-returned conveyor system. The solution includes packing benches, goods lifts, rack labelling and a new warehouse management system (WMS) supplied in conjunction with partner IDC.
“This was a very important project for us,” explains managing director contract logistics, Steve Hicks. He continues, “It has been almost five years in the planning; in 2019 we secured a suitable green-field site for this design and build project, breaking ground in 2020. A huge amount of work went into ensuring the project would be a success and this started with assembling the right partners.
“To guide us we employed the Supply Chain Consultancy Group who drew up a list of 12 potential suppliers. To start the process, we appointed a panel of seven stakeholders to evaluate the supplier submissions. The panel’s decision to appoint BS Handling Systems was unanimous (7-0); a winning margin which in itself speaks volumes about their solution. It was crystal clear that BS Handling totally understood the brief and our KPIs.”
A complex site with a fluid design spec
Noatum’s DC is 20 metres high with a footprint of 150,000 sq. ft. The four mezzanine floors above the ground level are an integral part of the building structure and account for an additional 228,000 sq. ft. A great deal of time was invested in the design phase to ensure the solution would meet the differing needs of Noatum’s customers – the site handles the retail, wholesale, eCommerce and eCommerce returns for at least five customers.
Steve Hicks again, “Because of our customers’ needs, BS Handling Systems had to cope with many adjustments on the fly, and I must say they were excellent at calmly working out solutions. “Their professional yet friendly approach helped build the excellent relationship we have with them. The entire team are very customer focused and throughout the project they ensured each part of the installation was completed on time and to specification.”
The challenge of moving to a new DC
“We transitioned from our traditional manual pick and pack operation at our old Rochester site over several weekends. Eventually, this meant our staff finished on Friday operating with the old methodology and came in on Monday morning to our new semi-automated Medway facility with a new WMS.
“That they were able to quickly get to grips with the new way of working is testament to the solution BS Handling Systems created. The systems simply worked from the get-go.
“Not surprisingly, with the varying requirements from our multiple customers, one of the most demanding aspects was the integration of the new WMS. It’s a challenge keeping everyone happy but BS Handling and IDC continue to work closely with us as we refine the system.”
Looking towards the future
“There is no doubt that BS Handling Systems has played a major role in the success of this new DC. To care for us now and in the future, we have invested in an ongoing maintenance and support package with them. This gives us real peace of mind with access to a 24/7 helpline with a guaranteed call back time within half an hour,” concludes Hicks.
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