Location: Elgin, Illinois

Application:

Integrated distribution center with paperless pick system, carton flow rack, conveyors, order routing system, dunnage dispensers, and carton sealing equipment.

This new DC consolidates several off-site locations and centralized others that were compartmentalized in the older building. Building restrictions limited the size of the new structure due to available land and sloped site.

Customer Situation:

Cook Communications Ministries, publishers of Christian books and educational materials, has been located on the banks of the Fox river for the past hundred years. During that period, the company prospered and acquired a number of similar operations. In order to provide enhanced customer service, the owner required consolidation of five operations under common roof, increased order accuracy with increased picking speed, and required interface with a new WMS.

The combined operation distributes approximately 7,000 SKU with an order level of 1700 per day average, peaking to 3700. Future growth is expected to double the order amount.

• Assisted CCM in benchmarking operation
  
• Designed system to fit limited footprint
  
• Developed interfaces between CAPS and JDE
  
• Furnished, installed, and wired entire system
  
• Provided picking deck with utility lighting
  
• Provided, installed and wired VC for pallets.
  

Benefits:

Cook Communications Ministries is realizing improved pick accuracy and speed by condensed pick faces in carton flow rack. Orders are automatically routed to appropriate zones via bar coded license plate and bypass non-picking zones. Shipping carton size is determined by means of order cubing software.

Supervision is facilitated with the new equipment layout and order status inquiries are accomplished at nearly "real time" status.

Project Highlights:

Facility Location: 850 North Grove Avenue, Elgin, Illinois 60120

Size: 23,000 Sq.Ft. D.C. plus 3,000 Sq. Ft. Dock

Product Handled: Christian books, pamphlets, toys,

System Designer: CCM, WEi, Kingway MH

System Integrator: WEi

Types of Mezzanines: Rack supported with metal pan and plywood deck

Types of Conveyor: Gravity, Live roller, belt, ZP Accumulation manufactured by Automotion Inc.

Types of Storage Rack: Kingway Material Handling, wide span carton flow.