Robots Revolutionizing Order Sorting for E-commerce
As the world of e-commerce continues to expand rapidly, businesses are constantly seeking innovative solutions to enhance their logistics and fulfilment processes. A prime example of this transformation is exemplified by K-Parts, an online supplier specializing in scooter, moped, motorbike, and bicycle parts. Based in Harderwijk, Netherlands, K-Parts has turned to Prime Vision’s robotic technology to elevate its warehouse logistics, enabling a more efficient and scalable order sorting system.
The Need for Automation in E-commerce
K-Parts has established itself as a one-stop shop for two-wheeler enthusiasts, providing seamless access to a plethora of parts required for maintenance and upgrades. With its business on the rise, the warehouse operations team recognized a critical need: to automate the order-picking process. Manual systems had become impractical due to the diverse sizes and shapes of spare parts, which complicated the automation efforts.
Initially, K-Parts relied on a traditional manual order-picking system. Once an order was received, staff would manually select and package items, a method that was not only time-consuming but also prone to human error. This inefficient process led the team to explore the possibilities of automation, paving the way for their partnership with Prime Vision.
Introducing Automated Storage and Retrieval Systems (ASRS)
To tackle their order fulfillment challenges, K-Parts integrated an Automated Storage and Retrieval System (ASRS) into their operations. This comprehensive system begins the order process by custom-constructing boxes tailored to the specific dimensions of the ordered parts. Once the box is prepared, it is guided to a designated picking station where K-Parts staff quickly fill it with the appropriate items provided by the ASRS.
Following the packing process, these boxes move through a box-closing mechanism, gearing up for sorting and eventual delivery. This sophisticated system has significantly reduced waste and manual intervention, thereby enhancing the entire logistical workflow.
Overcoming Space Constraints with Robotics
One of the challenges K-Parts faced was how to efficiently transport these custom boxes and their contents through various stages of the picking process. With a staggering average of 365 orders per hour, and limited space, traditional conveyor systems were not a feasible solution.
To address this, K-Parts collaborated with Prime Vision to implement an agile fleet of robots capable of navigating the tight confines of their storage area. These robots were chosen for their high versatility and adaptability, making them ideal for transporting a variety of box sizes, up to 30 kg, around the facility.
The Power of Prime Vision Robots
Standing at 875mm tall with a loading surface of 80 x 60 cm, Prime Vision robots are fully autonomous, utilizing sophisticated mapping and routing technology. They navigate the warehouse seamlessly, conveying items to specified locations based on real-time data from the warehouse management system. This level of autonomy allows for high levels of efficiency, optimizing both space and time.
Richard Hagen, account director at Prime Vision, elaborates on the integration: “We supplied a fleet of eight robots dedicated to moving between the box erector and three picking stations.” Each robot is programmed to deliver custom boxes to the correct station in a precise sequence, ensuring a smooth packing process.
Scalability for Growing Demands
Flexibility is paramount in fast-paced e-commerce environments. The robotic system implemented at K-Parts is not only designed for current operational volumes but is also inherently scalable. By simply updating the facility maps, K-Parts can add or remove robots or adjust picking stations to accommodate fluctuating order volumes.
As Bram van Eikenhorst, operations manager at K-Parts, points out, “With bike parts, order volumes fluctuate significantly, particularly during warmer weather or following weekends.” The robotic system’s scalability allows K-Parts to tackle peak demand periods without overburdening their workforce.
Efficiency Meets Service Consistency
The collaboration between K-Parts and Prime Vision has proven to be fruitful, optimizing resource management and increasing productivity. By ensuring that ordered items and custom boxes arrive at sorting staff with minimal delay and no need to search, order fulfilment becomes highly effective.
With robots processing orders more rapidly, K-Parts can achieve higher fulfilment rates while simultaneously reducing labor costs and time. As Bram emphasizes, “Our order picking process never stands still, leading to significant efficiency gains.”
Robust Support and Integration
Prime Vision complements its robotic solutions with technical infrastructure, providing charging stations and backup units for seamless operations. They handle the full integration of robotic systems into existing workflows, ensuring that K-Parts can maintain smooth operations with 24/7 maintenance support. Remarkably, they can resolve 90 percent of issues remotely, minimizing downtime.
As Richard explains, “Robotic sorting is a compelling solution for any operation managing over 800 items a day. It not only streamlines processes but is also cost-effective, making it accessible for growing e-commerce firms.”
The partnership between K-Parts and Prime Vision not only enhances operational efficiency but sets a robust foundation for future growth, ensuring K-Parts can meet rising demand while maintaining a high level of service consistency.