Manual Sort Parcel Handling System Expansion
PROJECT SCOPE
System Design & Integration, Consultation & Analysis, Electrical & Mechanical Engineering, Warehouse Controls System, Mechanical & Electrical Installation
INDUSTRY
Parcel Handling, Fulfillment
Case Study Overview: Custom Conveyor Design Increases Volume & Efficiency of Existing System with Zero Downtime
The SilMan System Integration Team provided engineering, conveyor design, and implementation services for a West Coast “Final Mile Delivery” logistics provider. The solution resulted in a sortation system and unload expansion, increased hub capacity (cross-docking), system reliability, and improved team member effectiveness. The project was engineered and executed without interruption to daily operations.
Expanded Warehouse Logistics System for an Industry Challenger
The facility featured in this article is an excellent example of how this company has achieved success in competing with industry giants.
The location is a savvy choice. It is perfectly positioned within the greater metro Phoenix area to serve its growing population. Moreover, the facility is large enough to support future growth without relocation.
And grow it has! So much so that in recent years, the volume began to outpace the original system’s designed capacity.
After years of persistent growth in demand, the time was ripe to expand the facility, much to the relief of the local operations management!
As leadership contemplated an updated system, they turned to the SilMan Integration Team.
The companies have a long history of working together. Even as this article is being published, our teams are concurrently collaborating on additional system implementations.
After a detailed analysis, the SilMan System Integration team proposed adding a new 3K system to the current layout. The design would also increase the effectiveness of the manual sort team.
For some providers, the capacity at the facility could equate to an automated sort system. However, with the efficiencies achieved by their management style and team member training, the company can achieve the needed increase in output with a well-designed improvement to their current system.
Parcel Handling Conveyor Design
The expansion included three new Unload Doors, a primary High Volume Divert (HVD) Sort Tower, a secondary HVD Sort Tower (Outbound) for Hub Operations, and one new Van Line.
Speak to a key team member on this project
Meet David Rebata
For more information about this project or related topics, contact David by email or call directly at 510.409.6567.
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With over 1800 linear feet of new conveyors and sort towers, the project adds more than 30% capacity to the facility. Moreover, the newer equipment adds speed and reliability to daily operations.
The added Outbound HVD sort also provides additional capacity to the overall hub operation.
These added tools also increase inbound preload capacity: Six new outbound (hub operations) doors and increased preload slots with a new Van Line are cooked into the operation.
In addition, major portions of the expansion lie above the existing conveyance. Therefore, the installation of heavy-duty steel structures to support the new equipment occupied a considerable amount of time and attention for our onsite teams.
All programming and commissioning by SilMan Material Handling Controls Group.
Mission accomplished!
Updated Distribution Center (Gallery)
This custom-engineered solution adds volume, speed, and reliability to the existing parcel handling systems.
Click photos for fullscreen view.
System Design and Implementation Challenges
The new system was designed and installed on schedule despite the obstacles presented by a global pandemic and supply chain disruptions.
The system operates nearly 24 hours daily, precluding shutdown periods as a viable installation strategy.
Instead, the SilMan system design and implementation teams formulated a combination of night and day shifts and daily coordination with operations managers to access work areas.
Additional complications arose from the expansion design’s overlaid and intertwined nature with the existing operational equipment. Physical access to key areas was a constant challenge.
We can proudly say that the expansion project was executed efficiently and safely, with minimal interruption to current operations.
Learn more about the SilMan Material Handling Team. Looking for more? Take a deeper dive into distribution center optimization or our Comprehensive Guide to Efficient Parcel Handling Systems.
Project Management Scope of Work
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System Design: mechanical, electrical and assist in design controls
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City and county inspections, and third-party special inspections
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All start-up activities and final project deliverables
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Updated system drawings and documentation upon project completion
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Life-cycle services
Talos Engineered Products
Key Conveyor Equipment Partner
Talos EP provided all conveyors and chutes for the Buckeye project.
The quality of their equipment speaks for itself. However, it is what you don’t see in photographs that make Talos such a valuable contributor.
First of all, their interactive, collaborative approach is a perfect match for the SilMan style.
This commitment is most visible working with their engineering team. Their previsualization and Configurator technology reduce human error and speeds SilMan’s installation process.
SilMan has created an article featuring Talos and our company’s relationship. You may read it here.
Click photos for full-screen view.
Conveyor Design, Equipment and Components
| Company | Equipment |
|---|---|
| Talos EP | Parcel Conveyors, Chutes, Bolted Construction |
| FMH | MaxxReach Telescopic Belt Conveyors |
| Flow-Turn | Powered Belt Turns |
| Talos EP | Electrical Operated Floating Plows |
| Forbo | Belting |
| SilMan Industries, Unison WCS | Motor Control Centers |
About the Company
SilMan Industries (previously SilMan Construction) is based in San Leandro, Calif., with Engineering and Field Operations offices in Tupelo, Miss. The firm provides integrated turnkey solutions in the Industrial, Manufacturing, Distribution, and Public Works sectors.
Notably, in 2010 SilMan Industries was contracted to dismantle and remove the NUMMI assembly line in Fremont, Calif., transport the equipment, and reinstall the system in Blue Spring, Miss., establishing Toyota Motor Manufacturing Mississippi (TMMMS). This high-visibility project ignited the company’s meteoric growth, laying the foundation for SilMan’s national service area.
For more information, please visit www.silmanindustries.com/about.
Custom Conveyor and Controls for Distribution and Fulfillment
SilMan’s renowned in-house team of system integrators, engineers, and controls professionals provide premium material handling solutions. In addition to parcel handling conveyor design, they are noted for their commitment to collaboration and transparency throughout the development and execution of projects. The multiple-skilled team has a national footprint, providing materials handling systems and solutions throughout the United States, serving market-leading distribution and fulfillment companies in crucial logistics communities in Stockton, Amarillo, Atlanta, Huntsville, Las Vegas, and Omaha.
