A green field Leeds Distribution Centre for the UK and world markets, newly opened by specialist orthopaedic supplier, DePuy International Limited, can truthfully claim to be a hip operation.
This ultra-modern 6 300 sq metres showpiece of the Johnson and Johnson group, houses a 150 000 GBP state-of-the art multi-storage solution supplied by Warehouse Systems Limited and utilising Bito Storage Systems components.
At full capacity the new DC, at Tingley just off the M62, will hold 26 000 different orthopaedic and related SKU's for the UK and world markets outside North and South America - a stockholding which only at a cost value, represents at least 50 million GBP at any given time.
Jon Kimber, Distribution Manager for Depuy International Ltd, is proud of the flagship facility which has been in planning for three years and replaces an 'old, tired and inadequate' warehouse site three miles away.
"Medical products, particularly high-value specialised orthopaedic implants need special handling and storage and a high degree of environmental control and hygiene. Most of the implants, for example, are constructed of high grade steels and plastics, and in some cases, of titanium and cobalt chrome.
"One of the difficulties with such a vast range of product supplied to diverse markets is that some of the items are fast-moving and some are very slow moving. The top 500 products represent about 85% of throughput.
"For instance, our fastest-moving products are replacement hip and knee joints and trauma products. But even within the category we have to cater, just like clothing, for all the standard sizes but also for the extremes as well - very large and very small. For some of these items, we'll only move one a year.
"We designed the warehouse and sent out a specification to five different companies based on what we wanted. WSL came back with Bito components which was by far the best solution. It was compatible with what we had already - some Bito live storage was already in place and aesthetically it looked very good which was important for this site. And the price was right.
Constructed into four clearly defined areas beneath the graceful arches of the high-tech warehouse shell, WSL has prescribed a combination of pallet live and carton live storage together with long-span and standard static shelving. The Leeds-based company has earned a reputation as the top supplier in the North for specialized storage solutions. In this case the company specified Bito Storage Systems for the entire solution.
Neville Proctor, sales director for WSL said that they have worked with Bito on a number of turnkey projects and are very pleased with the quality and overall appearance of the product.
"This is a very specialized environment and the components need to be durable and should complement what is after all a pristine and prestigious international site for the Johnson and Johnson group," he said.
WSL have supplied 101 bays of pallet racking, four and five levels deep, which are serviced by Bendi truck in 2 metre wide aisles. These are used to store and handle heavy pallets of bone cement – previously handled at an entirely separate facility in Blackpool which closed at the end of November.
Over 500 carton live pick locations, configured in 27 bays 2,7 metres wide with five levels of tilt shelves provide storage for thousands of cartons of specialized orthopaedic products. These include sports injury straps; spinal support systems comprising rods and screws and trauma products including plates and screws used to brace or reinforce fractured bones. Orders from CLS are picked to a 45 metre long conveyor also specified by WSL.
Slower moving items are stored in 836 standard static shelving bays, each providing six shelves, 1 metre in width.
Heavier and bulkier products are stored in long-span shelving which is organised in tiers of 10 shelves, each 2,5 metres wide and serviced by a wire-guided high-rise order picker.
WSL were also contracted to relocate some existing shelving and CLS, and provide double skin steel partition offices at the site.
Neville says that WSL commenced work two weeks after the placement of the order and were on site for four weeks, completing on time for go-live in November.
"The DePuy site is a showcase of storage versatility which demonstrates the capabilities of WSL working with supplier partners such as Bito Storage Systems.
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