LEADING MEAT SUPPLIER DRIVES
PRODUCTIVITY WITH CIRRUS TECH AND KEPWARE
A top beef producer located in Dodge City, Kansas ships several thousand boxes of meat per hour. The company requires a system that can read 20,000 tags from 10 PLCs every three seconds—reading, processing and returning the data—to ensure smooth routing of boxes for delivery.
From the warehouse to the retail location, the system requires complete automation with no human intervention. Cirrus Tech designed an automation solution that could provide routing direction within seconds. Originally, the beef producer based its automation system on RSLinx drivers from Rockwell Automation with data collected from Allen-Bradley PLCs. However, the performance was not meeting the company’s needs. “The drivers were slowing down the process—draining 80 percent of CPU space to read and respond to the more than 20,000 tags each second. The system just wasn’t getting it done,” said Chris Fonke, EVP of Software, Services & Solutions. For Cirrus to help, it had to offer an automation solution that provides routing direction within seconds.
In order to meet the company’s performance requirements based on its large tag count, Cirrus Tech knew it was time for the customer to change its automation processes from their three dispersed plants. Cirrus Tech helped the plant pull data from dozens of PLCs and equipment, analyze the detail, and send direction back to the system controllers.
This customized Cirrus Tech Automation System solution easily filters information and provides direction within two seconds, a powerful single-point interface that interchanges data at lightning speed resulting in delivering a game-changing, extremely efficient solution to the customer.
With the gravity-feed conveyor of the Cirrus Tech Crane System, it's just first in, first out...So it just eliminates all of the touching for about 70% of your product.
In terms of receiving, I don't have to carry a pallet 100 feet, 200 feet. It's just 20 feet away to getting input into our Cirrus Tech Crane System and I can input between three and four trailers at a time.
With Cirrus Tech we will receive product and put it in a rack location - it's in the system with one touch. The next time we touch it is for order building, and so we plan to take a minimum of four touches out of the process. That's where the efficiency is.
By choosing “The Crane” ASRS System from Cirrus Tech, we will gain efficiencies through our entire warehouse; how we receive, rotate and shuffle back stock, cycle count and replenish pick locations. The real surprise will be the efficiencies gained on the load building side. Cirrus Tech’s “Crane” and voice solutions will help us in all areas of the warehouse.
The Cirrus Tech Crane System provided our company an opportunity to consolidate an entire warehouse (Norfolk, NE) into the existing warehouse here in Fremont, NE. It will incorporate 5 years of growth while providing less than a 5 year ROI with the efficiencies of the system.
My picking with the Cirrus Tech Directed Picking solution is at least 3 times faster and more accurate than when our employees picked orders manually using a sheet of paper.
The Cirrus Tech Crane System not only saved us from doing a costly expansion, it also helped us organize our warehouse in a manner that put efficiencies in places that we would have never realized by building a new warehouse.
A major advantage of the Cirrus WMS is being able to know where all of the SKU’s are at any given time. This is especially helpful during crunch times when that rarely requested item would otherwise have to be hunted down in the warehouse. Now, the system instantaneously tells us where to find it.