Home' MHD Supply Chain Solutions : MHD Jan-Feb 2015 Contents Leading Australian home appliance
manufacturer Breville has made a
significant investment in its supply chain,
recently relocating to a new, purpose-designed
national distribution centre at Minto in Sydney's
western suburbs. A key attraction of the Minto
site was its close proximity to an intermodal
rail container terminal, enabling improved
shipping container handling efficiencies, a key
supply chain driver in Breville's high volume
international product-sourcing operations.
Being able to transport containers from
Port Botany direct to the new Minto DC by rail
eliminates a lot of the time and unnecessary
handling and transport costs associated with
receiving containers by road transport, said
Breville's logistics manager Stuart Roche.
"With the majority of our product range manu-
factured overseas, we were very keen to take up
the opportunity that adjacent intermodal con-
tainer handling facilities provide near our new
DC, and this was a key driver in the DC's design
and layout," he said.
The 15,000 m2 DC is situated on a four-
hectare site, incorporating its own 5000sqm
container storage park, and is designed to
provide the optimum combination of space
efficiency with fast, efficient access to stock.
The DC includes a high-density ColbyRACK
pallet storage system housing over 20,000
pallets, plus a compact very narrow aisle (VNA)
storage system for small parts picking.
Dematic's Rod Brooks said: "A high level
of pre-project design collaboration between
Dematic, Breville and the developer of the site
has resulted in one of the most impressive
warehouses in Australia."
Safety and space-
efficiency the keys
Operator safety and space-efficiency were key
drivers in the design of the ColbyRACK storage
solution for Breville, said Mr Brooks.
Main features include a seven-pallet high,
double-deep ColbyRACK storage system with
a top beam level of 10.2m, a full suite of Colby
Protect-a-Rack systems to prevent storage
system damage during pallet put-away and
retrieval, plus an 'eco-friendly' pedestrian safety
rail and guard system to segregate pedestrians
from areas where materials handling equipment
is used. High-density plastic moulded compo-
nents mean the safety fence absorbs impacts
and springs back into position, and because the
components are coloured, they don't scratch or
show any signs of marks even when hit.
Breville has also gone to the extent of
installing steel angles in the floor, in line with the
pedestrian segregation system. The steel angles
provide a high level of safety for pedestrians
within walkways by making sure that a forklift's
forks or pallet cannot be pushed under the
safety rail into the pedestrian walkway areas,
further reducing the potential for accidents.
The new DC replaces two outdated ware-
houses at Botany totalling over 23,000 m2, and
delivers vastly improved logistics support for
Breville, significantly improving supply chain
velocity, productivity and customer service levels.
While a lot of Breville's SKU range is fairly
lightweight, the ColbyRACK storage systems
were designed to handle conventional weight
pallets, ensuring that any pallet could be
put-away in any location, optimising long-term
storage flexibility, added Mr Brooks.
Guides improve pallet put-
away and retrieval
Self-centring pallet guide rails are installed within
the upper four levels of the double-deep racks to
assist with safe pallet put-away and retrieval.
"The guide rails in double-deep storage
systems, especially those in higher bays,
can take quite a beating during day-to-day
operations. That is why Dematic uses heavy-
duty welded cleats with bolted connections
to secure the guide rails in our double-deep
ColbyRACK system. This provides a much
stronger and safer solution than Tek screws,
improving WH&S and reducing long-term rack
maintenance costs," explained Mr Brooks.
Careful design detailing also optimised the
DC's pallet storage capacity. By locating building
columns within the void between the back-ties
of adjacent racks, no potential pallet storage
locations were lost in the final layout.
15,000m2 DC at Minto.
MHD SUPPLY CHAIN SOLUTIONS --- JANUARY / FEBRUARY 2015
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