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Inspiration from Practice - EMANS at LUNYS Increased the Picking and Packing of Goods by More than 50%

2017-07-04

APPROACH LOGISTICS WITH LOGIC

Lunys is a prominent Slovak company involved in the import and distribution of fresh and packed fruit and vegetables. It also handles the import and distribution of herbs, mushrooms, peeled products, exotic fruits and berries. The company’s main seat is in the town of Poprad, while the branch in Bratislava is responsible for wholesale and retail sales within the HORECA segment and sales network for western Slovakia.

INITIAL STATUS

At the branch in Bratislava with a warehouse capacity of 7,000 m² the staff had to pick and pack an average of 600 orders and deliver 3,500 crates to customers every night. Each crate was different – based on the customer’s order. It meant that thousands of items - almost 40 tons of fruit and vegetables, passed through the hands of the staff.  

All of these items were also manually registered on paper delivery notes which included the weight of the goods. The information from the delivery notes had to be entered into to the accounting system.

INITIAL STATUS AT LUNYS

time FOR A CHANGE

Lunys was constantly growing and adding more and more customers. The company realized that the existing processes of storing and picking and packing goods could not be maintained any longer. The utilization of the warehouse and human potential was 100%. The existing situation resulted in the need to find and implement a solution that would enable the company to radically improve productivity while preserving the high quality of its goods and services. 

From among the selected proposals of solutions delivered to the company, Lunys trusted the EMANS solution designed by ANASOFT.

TIME FOR A CHANGE AT LUNYS

LET’S GET THE GOODS MOVING TOGETHER

In order for Lunys to deliver fresh and fragile goods to customers who demand and expect reliability and quality, the classical system of automation and robotization was not possible. The goods placed by the operators in crates for chefs in hotels had to be in perfect condition and had to look good even after delivery.

Based on the proposed solution, it wouldn’t be the operators who moved around the warehouse with crates, but the goods themselves. The digitizing of the entire process of preparing crates and creating individual picking and packing stations for operators and the conveyor belt which moved the crates from one station to another became the basis. 

LET’S GET THE GOODS MOVING TOGETHER AT LUNYS

HOW DOES it all WORK?

Each operator has his/her station by the conveyor belt and is allocated his/her own assortment of goods to be placed in the relevant crate according to the electronic order displayed directly at his/her station. Digital scales which are built into the conveyor belt automatically weigh the added goods.

This solution could only work if the information sharing among individual workplaces was faster than the transport of goods on the conveyor belt. For this, EMANS created a “social network” of the plant. All of the information and its flow were converted into electronic form. Each crate, each warehouse station, each workplace has its digital twin. All of these components of the network communicate with each other via EMANS.

Operators have touch screens in front of them where the system displays all of the necessary information. The crates are equipped with RFID chips, and RFID antennas are deployed along the entire conveyor belt; they are also digitized, and thus all of the documents – starting with the order all the way to the delivery note are also updated online. 

HOW DOES IT ALL WORK?

HIGHER PRODUCTIVITY AT LUNYS

The individual workplaces at Lunys are equipped with mutually communicating PCs which exchange information, all of which is coordinated with the conveyor belt which knows what to do with each specific crate.

After implementing the EMANS solution, the Lunys plant in Bratislava now processes 800 orders with almost 10,000 items every day and delivers them throughout western Slovakia. Every day they dispatch 4,000 crates loaded with 50 tons of fruit and vegetables.

 

BEFORE implementing EMANS
(1 DAY) 

 AFTER implementing EMANS = 50% SAVINGS 

 600 orders  800 orders
 3,500 crates  4,000 crates
 40 tons of fruit and vegetables   50 tons of fruit and vegetables 
 8 - 10 hours  8 - 10 hours
 20 operators  10 operators

 

Adjusting the process, changing the technology and implementing EMANS resulted in an increase in productivity and a radical decrease in costs. Now, 10 operators pick and pack goods in 8 - 10 hours. Before, such volume of orders required the work of 20 operators.

The radical change in the need for staff training has been another benefit for Lunys. Previously, the training of new staff (becoming familiar with the warehouse, knowing where individual goods were located, distinguishing similar types, etc.) took several weeks. Today, a new employee is trained in a day.  Thanks to the simplicity of the picking and packing process and the visualization of all necessary information via the terminal, any new employee can be fully involved the day after starting the job.

The digitizing of the warehouse and connecting the conveyor belt to the information system was also beneficial for the operators whose work became much easier. The fact that everything operates digitally (no paper with delivery notes and orders) means that the proper information is provided at the proper time and in the proper place. 

ABOUT LUNYS

Lunys, spol. s r.o. is one of the most important suppliers of fruit and vegetables in Slovakia. It also processes fruit and vegetables for immediate consumption.

LunysThis company provides the possibility to use transport services with their own fleet of vehicles. It will deliver goods for customers and if necessary even with refrigeration.

The company also delivers its products to schools and is an active participant in the School Fruit program which is supported by the Slovak government and the EU.   
Learn more about this company at 
www.lunys.sk

Are you interested in learning more about the benefits provided by the EMANS solution for your company? Contact us. Arrange for a personal meeting to obtain more information