Bunzl's new trucks are equipped with RFID technology.

Healthcare specialist Bunzl has replaced its existing fleet of VNA (very narrow aisle) order-pickers with three Jungheinrich EKX 513 Kombis after reviewing operations at its Leicester distribution centre.

The new trucks are equipped with RFID technology that enables Bunzl's warehouse management system to automatically guide them to the right location in the aisles.

Bunzl supplies a comprehensive range of disposable healthcare consumables to the healthcare sector. The Leicester facility serves hospitals and other clients from Oxford to Sheffield and the previous fleet had grown tired and couldn't keep pace with the centre's high throughput levels.

"We clearly needed to invest in new materials handling equipment and processes," says Bunzl's operations director, Mike Parsonage. "We put the contract out to tender and were very impressed with the kind of productivity gains that the Jungheinrich products offered."

The RFID warehouse navigation unit, which is built into Bunzl's new trucks, has been designed to enable the operator to receive picking instructions from the company's warehouse management system.

Once the instructions have been transmitted, the operator accepts the command via a terminal and the system automatically guides the truck to the location in which the goods are stored. On reaching the storage location, a light on the side of the truck signals to the driver whether he has to pick the order from the left or the right.

According to Jungheinrich, the result is a significant improvement in picking accuracy as the operator cannot go to the wrong location and picking mistakes are therefore reduced.

The truck also travels via the shortest route and at the optimal speed, ensuring minimal energy consumption.

VNA order pickers have traditionally been guided by magnets buried in the warehouse floor. However, Jungheinrich says such systems do not offer the flexibility, safety and operational efficiency benefits of RFID transponders.

Bunzl was also impressed with the safety benefits of the RFID system. The transponders can sense if the truck is approaching the end of an aisle or a transfer aisle within the racking and will slow the truck's speed accordingly.
The truck's travel speed will also be optimised to suit floor conditions. If a part of the warehouse floor is uneven, the truck's speed will be reduced automatically. Also, when travelling with the operator platform raised and approaching a height obstacle likely to endanger the operator, the truck is brought to a controlled stop.

Bunzl's new trucks were delivered and installed over a weekend to minimise disruption to the distribution centre. The RFID system is expected to go live later this year once the company's warehouse management system has been upgraded.

Parsonage says the company is already benefiting from increased throughputs, lower running costs and higher productivity. "Furthermore, all the operators have commented on the better working environment in the comfort cab and the smooth ergonomic controls."

The value of the contract is confidential.