05/11/2011
Logistex crane upgrades give big boost to United Biscuits productivity, service and safety

Logistex has recently refurbished and upgraded 22 automated high bay cranes originally installed by the company in United Biscuits’ Ashby-de-la-Zouch Midland Distribution Centre. A combination of innovative upgrading and refurbishment technologies has resulted in significant improvements in productivity, service and safety, including a 27% increase in capacity, errors down by nearly a half, and faster, safer repair and maintenance procedures.

The 305,000ft² distribution centre holds some 58,000 pallet loads of famous branded sweet and savoury snacks including McVitie’s, Jacob’s, Carr’s, McCoy’s, Hula Hoops, McVitie’s Jaffa Cakes, KP and Mini Cheddars. Products arrive from various manufacturing locations and are held for shipment to the leading UK retailers and wholesalers.

In a fiercely competitive retail sector, United Biscuits’ clients constantly strive to improve their customer service and performance and increasingly look to their suppliers to support their efforts. With a portfolio of much-loved brands going back over 100 years, the company continually recognises the need to review its operations to maintain its reputation and high standards of service to leading retailers and to its loyal consumers. With demand for its products steadily growing, United Biscuits experienced more peak outputs in 2010 than in the previous four years – and all in a market where customer service is Key.

Under the code name “Raleigh”, United Biscuits management identified a number of key performance areas to improve still further its speed of response, flexibility and ability to accommodate retailers’ changing demands.


With the twin mantras of “Making good better” and “Maximising productivity through developing our assets”, the company worked extensively with long-term equipment supplier and partner Logistex to explore the options available to develop the equipment, systems and infrastructure to meet or exceed customer demand, and to raise plant productivity still further. Without improved performance United Biscuits might have faced the need to use external storage, adding cost with less control over their business and a potentially less efficient service.

Logistex proposed a hybrid solution of upgrading and refurbishing the existing cranes, which had the major attraction of costing far less than replacement - a virtually impossible solution given the need to maintain product deliveries – and could be carried out with minimal disruption to day-to-day operations. Such a programme also significantly reduces the risk of obsolete component failure - often the cause of much anxiety to management keen to keep meeting customers’ delivery expectations - which increases as systems begin to age. Losing functionality for a short time can be disruptive but extended downtime can have a far more serious impact to any service-focused business.

The programme included replacing the original Siemens S5 controllers with the latest Simatic S7 PLCs, specifically designed for automated systems and with Profibus capability. They provide a more powerful and improved real-time response with a larger program and data memory. With a range of expansion modules they can easily be adapted to respond to further developments and changes in demand, key factors for United Biscuits.

Replacing the hydraulic controls with electrical systems not only provides a more efficient and controllable process but also eliminates the product contamination risk – not to say the disruption – of oil leaks. With health and safety issues an increasingly important factor, Logistex have also installed on-board cameras, so staff can identify problems quickly and no longer need to climb up the crane to see what is required. With remote resetting another new feature, faults and errors can be overcome more quickly and safely. In addition, a faulty crane can make its way back automatically to a P&D station for attention thanks to the new control software, saving additional time.


As a tightly managed and professional organisation, United Biscuits has monitored and measured the way in which the upgraded cranes have performed in the first few months and the effect it has had on the organisation. The results are impressive and show significant improvements across the business.

Individual crane movements have risen by a third, from a maximum of 22 per hour pre-work to 34 per hour on the machines with the new electric platens, with individual movements up to 35 per hour. Errors have dropped dramatically by 45% and crane availability has risen from 88% to 95%. As a result the upgraded crane zone is able to ship up to 1,050 more pallets per day, a significant increase in performance, with 20 more lorries leaving every day.

The project was carried out over the summer of 2010, with individual cranes taken out of operation one at a time to avoid disruption or delay, and with work being done whenever possible during quieter times. With regular dialogue between United Biscuits and Logistex teams, the project was completed within a tight time frame in September 2010, in time for the next peak period.

United Biscuits Mike Howells explained how the companies worked together on the project. “We have worked closely in partnership with Logistex over the past 20 years, during which time they have supplied our high bay automated crane systems and continue to provide an on-site maintenance team to support us. They understand what our business is all about – outstanding service to our customers – and with their experience of big projects it made obvious sense to involve them from the beginning in the Raleigh project.”

“They quickly grasped what we were looking for and could see the risks and the opportunities involved, including the need to stay operative throughout the programme as we could not risk delays or non-deliveries. We were impressed too by the way in which their senior management team got involved, which showed their commitment to delivering the best result possible for us. It took time for the joint team to investigate and research the various options and they came up with a number of fresh and innovative ideas, rather than simply trot out a standard solution.”

“As well as making sure we completed the project on time, Logistex took on board our strong corporate focus on safety and environmental issues. Features such as
on board cameras and doing away with hydraulics, although not initally considered, fitted in well with our philosophy.”

“The project was meticulously and safely managed, with equipment deliveries fitting in with the demands of our operations. We did not hear a word of concern from our customers and while we used to think that shipping 5,000 pallets a day was good, we can now manage 6,000 without a problem.”

In summary we have what is in effect a new automated crane system using the latest technology and fit for a decade or more, but at a fraction of the price and virtually none of the disruption. It sets new levels of safety and productivity and means we can continue to deliver on our promises and meet whatever demands the big retailers make on us.”
 

05/11/2011
Logistex wins food handling and storage project

Logistex has won an order to supply an integrated order forwarding system for a leading cake and food decorating product supplier. The equipment will be installed in Culpitt Ltd’s newly extended Northumberland warehouse facility.

The project includes the supply and installation of a conveyor system, a raised storage platform, carton live storage, push back and adjustable pallet racking. Work is expected to start late 2011 for completion in early 2012.

Culpitt Ltd is the UK’s leading supplier of cake and food decorating products and the UK’s largest wholesaler of sugar crafting edibles and equipment.
 

05/11/2011
Logistex upgrade adds improved performance and new life to automated warehouse

Logistex has recently completed an extensive modernisation and upgrade programme to a leading distribution company’s automated high bay installation in Oxfordshire. Originally installed by Logistex 1995, the system had served the client well during a lengthy time of changing market conditions. However what were once state-of-the-art technologies were starting to become obsolete and the client identified specific areas for improvement to help maintain its growth and competitiveness in the market.

The former aging, single client WMS software has been replaced by Logistex’s own Logistex Warehouse Management System (LWS), which now provides the user with multi-client capability, as well as improved productivity, flexibility and response. The result of several decades of experience in developing software systems, LWS is a user-friendly, modular and fully configurable single solution for warehouse management.

Logistex has also replaced the original Siemens S5 PLC controllers - which have been phased out by the manufacturer - with the latest Simatic S7 PLC, specifically designed for automated systems and with Profibus capability. They provide a more powerful and improved real-time response and have a larger program and data memory. With a range of expansion modules the LWS can easily be adapted to respond to further developments and changes in demand.

The project will provide a far more flexible, future-proof and reliable system for the next decade at least, able to handle the mix of clients and products needed to maintain maximum profitable utilisation of the 217,000ft² facility.

Completed at a fraction of the cost of a full replacement programme and without the inevitable disruption, the investment required will require a far shorter payback period and a more positive ROI – a strong argument in favour of upgrades in the present economic climate.

The temperature controlled facility holds some 42,500 pallets with 550 SKUs and is served by ten Maestro automated fixed aisle cranes. Orders ranging from full pallet loads to multi-part shipments are dispatched seven days a week to leading retailers, wholesalers and other key accounts.

Logistex continues to provide fast, effective on-site support, ensuring the maximum up-time availability and performance. Replacing older components in the system will ensure long-term continued spare parts availability and system reliability.

In a significant extension to its services, Logistex is now providing the client with full Site Engineering and Facilities Maintenance support covering almost every aspect of the building and systems - including handling and storage equipment, heating and energy management, utilities and services, building fabric inspections, safety and environmental issues, legislation compliance and insurance.

 

05/11/2011
Logistex completes second ASRS upgrade and storage systems contract for Wincanton

Logistex has completed a second contract for Wincanton plc to upgrade Automated Storage and Retrieval Systems (ASRS) in distribution centres operated by Wincanton on behalf of GlaxoSmithKline (GSK).

The first contract was to add two high bay storage aisles with narrow aisle cranes to the existing nine aisles installed by Logistex, as well as additional racking and conveyors, in Wincanton’s GSK Distribution Centre at Middlewich, Cheshire. The second contract was to upgrade the ASRS - originally installed by a different supplier - at Wincanton’s GSK Distribution Centre at Brockworth, near Gloucester.
In the Brockworth upgrade, Logistex has replaced legacy control technology, operator screens, motors and drive components with software and equipment based on next-generation technologies. They have made significant improvements in system functionality, including providing all 15 cranes with the flexibility to change aisles.

These enhancements form part of the development of the supply chain infrastructure to support the growth of GSK’s Consumer and Nutritional Healthcare business.
Gerry Bonnar, Wincanton's Contract General Manager, commented: “The new system has not only enhanced the centre’s efficiency but is also providing a platform for continual improvement of the working environment for employees”.
The project has brought a number of operational and safety improvements to the warehouse. ASRS cranes can operate in either automatic or semi-automatic mode, adding further flexibility and ease of maintenance. The new control system allows cranes to automatically return to the home position when an error is detected, and has a timer and diagnostics system that provides faster, more responsive and safe maintenance and repair. An interlock key exchange and new light guard have increased safety and new AC motors will reduce energy costs and improve reliability.

Martin Sealy, Business Unit Director for Wincanton, commented further: “We have been impressed by the solution provided by Logistex – its flexibility and features will facilitate agility and growth”. Martin Cooke, GSK Distribution Operations Manager, added: “The solution they presented to upgrade the Brockworth site was sufficiently innovative and impressive for us to award them the contract.”

Jerry Woodhouse, Managing Director, Logistex, summed up: “Refining and developing materials handling efficiency is a continuous process. Logistex’s consultative and flexible approach to system upgrades allows customers to implement ongoing cost-down initiatives which enable them to maintain a sharp, competitive edge”.

13/09/2011
Logistex upgrades at United Biscuits short-listed for European Supply Chain Excellence Award

Logistex has been short-listed in the Logistics and Distribution Operations Category of this year's European Supply Chain Excellence awards for a refurbishment and upgrade project carried out for United Biscuits.

The awards are sponsored by Supply Chain Standard, published by Centaur Media, who also publish Logistics Manager journal. The results will be announced at a gala dinner on 1st November at London's Grosvenor House.

At United Biscuits' Ashby de la Zouch distribution centre, Logistex's upgrade programme for the existing automated warehouse improved crane availability, cut errors by half and increased crane movements by a third, while the business continued uninterrupted.

20/02/2011
Logistex gains independence with successful Management Buyout

Logistex is pleased to confirm that it has completed a Management Buyout with the business having been acquired by the existing seven-man management team, which over the past three years has transformed the company into a financially robust, profitable and successful organisation. The MBO was achieved without external financial support, leaving the company debt- free and with a strong balance sheet.
Managing director Jerry Woodhouse was keen to provide reassurance that it will still be business as usual for clients, employees, suppliers and other business partners. “We have established a sound and successful business model and will continue to build on the same strategy, operations and services that are currently in place. Our head office in Kettering will continue to be our centre of operations with the same team and organisation.”
“The big difference the MBO will provide is that we now have the freedom and flexibility to deliver the solutions, services and standards to meet the needs of a fast-changing international marketplace. We have an experienced, qualified and well trained staff of some 225 with outstanding expertise in all the key disciplines and are full equipped to tackle most projects.”
The most fundamental decision was to move away from manufacturing and to become a 4Pi, or 4th party integrator. As a result Logistex now provides a full project integration and management service by sourcing and combining equipment and services from “best in breed” specialist suppliers wherever they may be, together with its own software and IT systems.
The company has continued to maintain software development and systems in-house, building on its legacy expertise going back almost half a century.
Supporting its existing systems with long-term maintenance agreements not only provides clients with reliable and productive systems - it also means that the company can safely predict sufficient revenue at the start of each financial year to cover its costs, providing the bedrock for profitable trading.
The Logistex management team comprises:

• Jerry Woodhouse Managing Director
• Mark Nicholson Financial Director
• Kevin Sheridan Operations Director
• Andy Branch Engineering Director
• Melvin Macartney Projects Director
• Derek Kay Head of Systems
• Keith Edmonds Head of Sales

You can download a pdf copy of the full announcement by clicking on the 'Download PDF' icon associated with this news item.

20/04/2010
New General brochure available for download

Available from today as a downloadable pdf is the Logistex general brochure focused on automated warehousing and our 4Pi offerings. Within this brochure are details on the rolls we play in:

• Solution design
• System control
• Project delivery
• Total lifecycle support

This is the first in a series of brochures and other detailed documentation which we are making available as both downloadable and hardcopy documents.

29/01/2010
Spicers Award Upgrade Enhancement Project

Spicers continues to invest in the Sawston site near Cambridge and as a result has awarded Logistex with a significant upgrade and enhancement project. Logistex delivered the original solution 11 years ago and has ensured effective performance via its Lifecycle Support Team during this time.



Works starts immediately and Logistex looks forward to ensuring successful implementation for Spicers by the end of 2010