A pallet flow system with push-back and pallet live lanes
Adient Seating UK Ltd's existing manufacturing facility in Burton-upon-Trent, Staffordshire, originally utilised a bulk plastic, pallet box stacking system for the storage of raw production materials and empty stillages. Although this was managed by an experienced materials team, it offered inefficient picking and stock rotation, limiting Adient’s just-in-time manufacturing process, which is driven by their client's own production schedule.
Adient, therefore, engaged with SEC Storage to help develop a solution that would increase their overall materials flow. In order to identify a solution, SEC Storage carried out a detailed operational analysis of Adient’s production and SKU data on a volumetric, cubic and quantitative basis, which identified a unique operational need.
SEC Storage found that Adient’s production starts with the arrival of multiple types of pallet boxes filled with individual seating components. When an order is received, individual components are picked from varying boxes to create a seat kit. This seat kit is then taken by an automated guided vehicle (AGV) to the main production area. From here, finished goods are despatched to the customer.
In order to make the picking process as efficient as possible, SEC Storage identified the need to separate the stock holding and replenishment from the picking operation. The design was based on a pallet racking structure, which includes push-back and pallet live lanes, enabling the simultaneous storage, pick and replenishment of materials.
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