Smyths Toys,
Walsrode (DE).
A logistics challenge
Retail & e-commerce combined in one warehouse.
After Toys ‘R’ Us were taken over by Smyths Toys in Germany, Austria and Switzerland, a new centrally located warehouse was needed in Germany to serve both the company’s own stores and the private customers using the online shop. A great logistics challenge!
The challenge
Scalability and smart exchange retail and e-commerce
Smyths Toys was looking for a total solution for this new warehouse. A combination of hardware and software was needed which enables a smart exchange between retail and e-commerce. The warehouse layout had to be able to handle high peaks during Christmas and Black-Friday, scalability plays a major role in the realization of the warehouse.
High storage density
Zone picking with pick to light
Smart software
The solution
Smart hardware & software.
Optimal coordination between the WMS, ERP and hardware is crucial. Because these systems work together continuously, they always show the location of items in the warehouse and where items need to be delivered: replenishment for retail, replenishment of e-commerce inventory, order picking or shipping of goods.
The solution
How does the WMS work at Smyths Toys?
At Smyths toys, the warehouse serves both retail and e-commerce. The WMS takes care of the entire internal transport. The WMS has insight into the stock; where & how many items are present. The software also controls the hardware, so that the items are transported internally in the right way.
The link with the stores, webshop and transporters is made by linking the WMS to the ERP system (SAP). For example, the routes for the trucks and associated docks are linked to the nearest conveyor (chute).
The solution
Retail & e-commerce:
Inbound & replenishment
For inbound, articles are scanned with a handterminal upon entry. The WMS determines the storage location within the warehouse via the set strategies. The WMS then controls the hand terminals and the VNAs (very narrow aisle forklift trucks) of the inbound employees.
VNAs provide high-density storage
The VNA (very narrow aisle) drivers see on their screen which pallets they have to pick up and where, and the location to which they must take them. The use of VNAs, in which the forklift’s forks can be turned sideways, saves a lot of space and enables high storage density.
Conveyors for automated intern transport
The stock of the web shop is stored separately and conveyors are used to move items to the stock of the web shop. In the webshop area, the stock is tailored to the demand of the webshop.
Items can also be transported from the inbound or warehouse via the conveyor to the correct chute for the store in question.
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The solution
WMS for webshop.
The WMS prepares orders A to Z for transport and ensures that the right package reaches the right carrier. Conveyors play an important role in this. Many boxes go over these conveyors simultaneously. In order to deliver each order at the right time and in the right order, the WMS controls the priority of boxes on the conveyors.
Order preparation
Preparing the order starts with a suitable box. The software controls the carton erector for this purpose. A box should not contain unnecessary “air”, but there should be enough space to combine items from the same order. After the box is filled, the box automatically receives the correct barcode through the label applicator and proceeds to the order picking process.
The solution
Zonepicking.
The box with label goes via conveyors up one floor to the zone picking system. The WMS sends the box in the right order along the zones; first along the articles with the largest size and weight, then along the lighter/smaller articles, thus creating the right pressure distribution.
By using zones for order picking, order pickers never have to walk far or lift anything. This increases the efficiency of the order picking process and improves working conditions.
Pick to light.
Smyths Toys uses the pick to light system, where orderpickers see a lit light next to the articles they have to pick. Pick to light is the ideal solution for employees with various language backgrounds.
Packing & checking
When the order is complete, it goes via conveyors to the pack & check stations where the orders are checked and packed.
Starting a successful
cooperation?
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Outbound
The articles placed on the conveyor are linked by the WMS to the orders and corresponding truck routes. Based on this, conveyors are controlled and these articles are moved to the right chute. There, the boxes are placed on a pallet: on their way to the shops.
The orders for the web shop arrive directly via separate conveyors at the dock of the right carrier where the truck is ready to be loaded!
The result
Stock stock on level, also in peak period.
The smart software provides insight into stock for both retail and e-commerce. The combination of seamlessly matched hardware and software makes retail and e-commerce stock transparent and easy to replenish. As a result, the current stock is up to date and peak periods can be absorbed. Dividing order picking with zone picking and supporting it with pick-to-light has increased the effectiveness of order picking.
Inspiration
Relevante projects.
Advice
Get in touch with our specialists.
Would you also like to start a successful partnership for your logistics solutions? Contact one of our specialists and we will be happy to help you with your challenges!
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