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THE PROBLEM
Walmart sought a fully automated, “lights out” each-picking process to fulfill store orders less than case quantity. The operation required storing up to 2,900 bins, each destined for specific locations across multiple stores, and organizing them by aisle for efficient delivery. Additionally, the project had to fit within a narrow, multi-level warehouse footprint while adhering to strict fire protection requirements. These challenges demanded a holistic solution capable of seamlessly integrating advanced automation with manual flexibility where necessary.
KEY QUESTIONS
- How can Walmart automate the process of each picking for store orders while organizing bins by aisle?
- What design can maximize storage within a constrained, multi-level facility?
- How can automation integrate with manual operations to handle exceptions efficiently?
- How can suppliers and systems be coordinated to ensure seamless implementation?
THE SOLUTION
Walmart partnered with Maveneer to design a holistic, fully automated each-picking solution that addressed these challenges.
Conceptual Design and Flow: Maveneer developed a system with three operational levels, each with double-sided, three-tiered tote storage. This design accommodated up to 2,900 bins within the constrained facility footprint, organized by store aisle to ensure efficient delivery.
Case Opening and Picking: Cases were partially automated for opening, with items picked individually for orders. Tilt-tray robots autonomously transported items to their corresponding bins.
Tote and Bin Management: The process automated the receiving, unstacking, and storage of totes and bins, reducing human handling and improving efficiency.
Manual Flexibility: Manual workstations were included to handle exceptions and provide redundancy for the automated system.
Supplier Selection and Coordination: Maveneer led supplier selection and managed the integration of technologies, ensuring seamless collaboration between all components.
Space Optimization: The design overcame significant constraints, such as the long, narrow facility layout and multi-level operations, while incorporating fire protection and safety measures.
KEY RESULTS & INSIGHTS
- Enhanced Efficiency: The solution eliminated unnecessary walking and manual handling, streamlining the each-picking process.
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Space Maximization: The design fit within tight space constraints, achieving a storage density previously considered unattainable.
- Automation Success: The process was fully automated, handling the receipt, storage, and retrieval of bins with minimal human intervention.
- Flexibility and Redundancy: The inclusion of manual workstations ensured operational continuity during exceptions or maintenance.
- Holistic Management: Maveneer’s oversight ensured successful supplier integration, procurement, and implementation of the complex system.
PROJECT PHOTOS
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