Semi-automated warehouse solution maximizes efficiency

This new solution for Draper Tools includes a flow-through rack with pick-by-light, large-span shelves, modular shelves and container lane technology. This efficient solution is based on the goods-to-person principle, saving storage space and optimizing transport times.

From jacks to wrenches: Draper Tools offers a wide range of hand and power tools and equipment for every need. Founded in 1919 by Bert Draper, the company sells more than 11,000 products through a worldwide dealer network to do-it-yourselfers and trade customers in the construction, automotive, engineering and agricultural industries. John, Tom and Joe Draper are at the helm of the British family business and continue to expand it diligently. But as the company grows, so do the challenges: To successfully manage the extensive product range, powerful and forward-looking logistics are now more important than ever.

Strong partners for top logistics performance

In 2019, Draper Tools turned to intralogistics expert SSI SCHAEFER for the relocation of order picking and storage to its new site in North Baddesley, Hampshire, UK. The aim was to make optimum use of the existing warehouse space, improve processes and reduce delivery times. A challenging task that could only be brought to fruition through particularly close cooperation:

"Throughout the entire project, the support from SSI SCHAEFER was exceptional. We felt we had a partner who not only worked with us, but for us. They took the time to understand our complex business processes and helped us refine them," states Matt Boschi, Operations Director at Draper Tools.

Comprehensive solution for maximum productivity

With the new semi-automatic solution from SSI SCHAEFER, even the management of large SKUs is no problem. This is provided by shelves that can be flexibly adapted to the widest range of items and individually extended in height, depth and section width, as well as large-area shelving for bulky and heavy stored goods.

Goods are collected in containers and transported to the second floor, where the whole process is repeated. There is a goods elevator for items too large for a bin. Seamless material flow is guaranteed: conveyor technology connects all levels and work stations up to packing and goods issue on the second floor. The ingenious but simple layout also saves valuable space and gives Draper Tools every opportunity for customization and future growth.

Process 11,000 SKUs (Stock Keeping Units).

Based on an initial automation idea, SSI SCHAEFER and Draper Tools jointly developed a solution that is perfectly matched to the tool wholesaler's warehouse layout, mode of operation and wide range of SKUs: 21 order picking stations with pick-by-light flow racks for the fast movers and shelves for the slow-moving items, which are connected via conveyor technology over three levels. The semi-automatic system with 420 bins and a capacity of 8,000 different SKUs is designed according to the goods-to-person principle and allows efficient order picking of up to 25,000 units per day.

Smart selection thanks to an economical shelf system

Once an order is received, the orders are assigned to totes that are automatically launched from the totes de-stacker. The totes are transported through the conveyor system to the flow rack system (KDR) on the second floor, where they are loaded using pick-by-light. The KDR is ideal for small parts and, thanks to its robust roller rails, ensures that the totes flow smoothly from the loading side to the picking side. This significantly reduces walking distance for employees, reduces replenishment effort and speeds up order picking. Thanks to the compact storage in the KDR, the available space is also optimally utilized. In addition to storage capacity, Draper Tools can also significantly increase the quality of processes: the pick-by-light system virtually eliminates picking errors and increases picking speed.

Success Tool

More storage capacity, better performance, higher customer satisfaction - the move to automation has already paid off for Draper Tools. Within just six months of commissioning the new warehouse solution, the main goals had already been achieved: "We have seen a significant increase in the speed of picking and packing, allowing us to serve our customers even faster. Thanks to the optimum scalability of the system, Draper Tools is excellently equipped for a successful future and, with SSI SCHAEFER as a reliable partner
continue to shape."