Three-level, double-deep pick modules help maximize the distribution center cube. Each of the picking lanes features a live roller takeaway conveyor with gravity conveyors on either side.

When an acquisition greatly expanded the customer base, Evenflo had to ramp up throughput-and do it fast.

For Evenflo, babies are big business. And that business got even bigger with the 1997 purchase of Gerry Baby Products. That acquisition dramatically expanded the Evenflo customer base while adding significantly to an already extensive product line.

Evenflo is one of the world's leading manufacturers of products for babies. Its original product line included feeding products such as breastfeeding equipment, nursers, and nipples. Over the years, the offerings have expanded to include high chairs, strollers, and baby furniture. The Gerry acquisition brought items such as car seats, gates, and bath products under the Evenflo umbrella.

With that growth came a challenge for the company's distribution center in Canton, Georgia, which handles distribution of the feeding products and the merchandise acquired from Gerry-1,100 SKUs in total. That challenge was to absorb a 70 percent increase in inventory and achieve a like increase in order throughput, all while keeping the operation running.

Evenflo met the challenge thanks in large part to creative expansion of the existing facility and implementation of integrated conveyor technology. Since the installation the distribution center has, in fact, more than doubled order throughput and tripled capacity.

Two Key Objectives

Evenflo moved into its current distribution center nearly five years ago. The complex at Canton also includes a large manufacturing facility. The company's corporate headquarters are in Vandalia, OH.

Orders pass from "the sawtooth merge" toward the high-speed QS-1 sortation conveyors in the background. Installation of this equipment has helped the DC more than triple throughput - from 9,000 to 29,000 cartons per day.

When it came time to expand the DC in support of the new inventory and order processing requirements, senior VP Michael Johnson assigned Mark T. Williams, director of logistics and company materials handling systems designer, to explore a number of options. They finally decided that building on the system in place made the most sense both financially and operationally. The Hytrol conveyor units that formed the heart of that system had performed well and required little maintenance. In addition, the distribution center had established a good working relationship with Conveyors & Drives Inc., a Hytrol distributor based in nearby Atlanta.

Evenflo had two key objectives in upgrading the Canton distribution center: (1) utilize the vertical cube by elevating the conveyor system and (2) open up access to the shipping docks and the pick modules for replenishment. Working with Conveyors and Drives Systems Group, and utilizing Hytrol conveyor equipment, Evenflo was able to accomplish both objectives. Just as importantly, it achieved these goals quickly and with minimal interruption in operations. The extensive installation was completed in under eight weeks.

To achieve the objectives, the Evenflo-Conveyors and Drives Systems Group team took a comprehensive approach that involved creation of new pick modules, expansion of existing modules, and adoption of productivity-enhancing conveyor technology. Throughout the installation period, the distribution center remained in continuous operation. Orders were manually assembled and shipped until the project was completed.

Two new pick modules were added to the Canton facility. These were built three levels high and featured double deep palletized storage locations. The two existing pick modules were extended 30 feet. The facility now has a total of ten 120' long picking lanes.

The QS-1 sortation unit automatically sends cartons down one of eight chutes, leading to the shipping docks. The elevated configuration helped Evenflo achieve its goal of increasing space and access in the shipping area.

The picking lanes are simple and straightforward. Each lane has a takeaway live roller conveyor (190-LR), which is flanked by two gravity conveyors for assembling orders. Cartons move from the pick areas on these live rollers (or in the case of the picking lanes on the ground floor on an incline roller bed conveyor) to a horizontal power conveyor. This elevated unit collects the orders as it runs and stretches the length of the building. It then makes a 180-degree turn and enters the orders into a zero-pressure accumulation conveyor that utilizes the Hytrol EZ Logic technology.

The EZ Logic accumulator (190-ABEZ) controls the flow of orders as they move toward a "sawtooth merge" conveyor and on to a high-speed sorter (QS-1). The systems work smoothly and efficiently, regardless of the workload demand. "The EZ Logic accumulation system does an excellent job of keeping pace with the sortation system," says Mark T. Williams, director of logistics and distribution at the center. "It handles everything that we throw at it."

The QS-1 sorter is key to helping Evenflo achieve its productivity goals. Directional scanners read the label on any side of the carton as it runs through the pre-induct. The high-speed sortation unit then diverts the carton down the designated chute, and then on to the skatewheel conveyors that lead to the staging and shipping areas. Eight sortation points assure maximum flexibility and capacity.

"The new QS-1 sorter allowed us to increase our throughput, which was the biggest challenge we faced when we absorbed all of the inventory from Gerry Baby Products," observes Shipping Coordinator David P. Winter.

Multiple Benefits Realized

The upgraded installation has helped the Evenflo distribution center reach its original objectives and more. Vertical cube space now is fully utilized with the elevated and expanded picking modules. Ten picking lanes efficiently keep pace with order demand. Throughput capacity has increased from 9,000 cartons per eight-hour shift to 29,000. And the elevated configuration of the conveyors and sortation equipment has opened up the shipping area, allowing for higher productivity and ease of movement.

All in all, the new system has enabled distribution center management to more effectively manage the flow of inventory and orders throughout the facility.

The bottom line tells the whole story: Evenflo can keep pace with a booming baby business that shows no signs of slowing down.

Evenflo's Enhanced Distribution Center

The order fulfillment process begins in the four multi-level pick modules.  The orders move form the 12 individual picking lanes to an elevated power conveyor that travels to the end of the building, makes a U-turn, and then enters the cartons onto the EZLogic accumulation conveyor.  This zero pressure accumulator controls the flow of orders as they move to the sawtooth merge conveyor and on to the high speed QS-1 sorter.  The sorter swiftly diverts the cartons down one of eight chutes to the appropriate shipping dock.