SAVOYE adds more efficiency to orderpicking process of SODITRA LOGISTIC

The goal of L’Oréal was to add more flexibility, reactivity, and above all more synergy to their process. In the end, this is why they decided to outsource all activities for the Benelux to their loyal partner Soditra Logistic.

This development kick-started an internal reorganization in which the activities for other customers will move to Mollem and the logistics services for L’Oréal will be centralized under one roof in Nivelles. This location will be expanded from 16,000m2 to 30,000m2, with a complete refurbishment.

Rearranging the logistic puzzle

The activities in Nivelles can be divided into three parts:

1. Complete pallets in and out
2. Standard orderpicking. The orderpicker collects products and builds up the complete pallet/order.
3. Detail picking; a box/package is built up with different items. At first, this was done with picking trolleys. In 2018, a new technology was implemented: AMR robots and mobile shelvings in combination with four picking stations.

The organization above was mainly determined by the rotation classes of the products; the fast movers and the slow movers, 20%-80% of the SKU’s in stock and 80%-20% of the flow of goods.

Now that all the L’Oréal work had to be gathered under one roof, the next important question had to be answered: “What is the best mix of systems and equipment to get everything done in the best possible way?”

The advantages and disadvantages of both goods-to-man and man-to-goods solutions were carefully analysed, keeping the rotation classes as a the starting base. Man-to-goods systems simplify the re-stocking process, but they provide less output. With goods-to-man solutions, it is exactly the other way around. A study was conducted to design the best solution.

After the zone with robots, the conveyor transports the boxes to the zone-to-zone picking area, where flow racks (goods are fed in through the back) and an amount of picking stations will be used. The open boxes are transported in front of them. RF technology is used to indicate the quantities to be placed in the box. Finally, the boxes arrive at one of the eight exit lanes to be prepared for shipment.

Remarkable and particularly efficient is the solution to remove the empty packaging from the picking stations. Savoye integrates an extra conveyor belt next to the main line, which will transport all waste material directly to a shredder.

Jean-Luc Waetermans, Business Development Director at Soditra Logistic explains: “It has been quite a puzzle to simultaneously expand and refurbish the premises in Nivelles. We had just one year to complete the entire process, during which it was no option to pause or stop the daily activities. Savoye helped us to come up with and to design this integrated solution. The cooperation is going according to plan and we expect to be fully operational in July. Including a more productive and efficient process in the warehouse.”