Automated Replenishment Solutions

The FKI Logistex automated replenishment solution uses mini-load cranes to reduce the high manual labor cost of split-case picking, increasing order fulfillment speed and accuracy.

When pallets are delivered in a typical FKI Logistex automated replenishment system, the trash and dunnage is removed and the product is immediately sorted and placed directly into plastic totes. A tote-based system eliminates the buildup of trash through the picking process and provides consistency when compared with systems that transport SKUs in their original boxes, which can vary in size. A conveyor routes the totes to the rack system, where mini-load cranes move the totes to static rack locations where they are stored as general inventory.

At the beginning of each wave, the FKI Logistex control system reassigns pick faces based on immediate demand to support customer orders or replenish store inventory. The mini-load crane automatically retrieves totes from the rack and fills up the necessary slots. The logic built into the system maintains a balance of static locations — fast-moving SKUs that can be changed to follow seasonality — and dynamic locations, which can be reassigned wave after wave to present SKUs needed for the next round of orders.

A combination of FKI Logistex EASYpick® GoKartTM, pick-to-light and pick-to-voice order fulfillment systems are used for picking totes, which are placed on a takeaway conveyor for routing to shipping and sortation. Empty totes are placed back on the same conveyer and are diverted back downstream for automatic stacking, staging, and routing back to tote filling for new SKUs.