SSI Schaefer worked with Kiddicare, now owned by Morrisons, in 2008 to install a pallet racking bulk store area and multi-level picking module with an integrated conveyor system into its then 160,000 sq ft warehouse in Peterborough – also home to Kiddicare’s flagship super store.
Following the brief to extend this system in December 2011, it took SSI Schaefer just seven months to finish the installation and provide Kiddicare with thousands of additional pallet positions and pickfaces for both cartons and small items, increasing the size of the warehouse footprint by 3180 m².
Kiddicare Logistics Manager, Steve Poulter, said, "SSI Schaefer has helped Kiddicare hit our expansion targets to support our rapidly growing multichannel business operation. The teams involved work effectively together to deliver the project on time and in budget." The Kiddicare warehouse, which stores a significantly high value of stock ready for despatch, currently supports a predominantly online business; however there are plans to open ten additional retail outlets across the UK, the first opening this Autumn. These stores will be replenished with goods from a new central distribution centre in Daventry.
Now comprising wide aisle, double-deep adjustable pallet racking, a substantial area of the original racking was removed, relocated and reassembled to accommodate a new three-tier rack-supported pick tower linked to the existing pick tower by high level bridge walkways to enable operator movement between the two areas.
The top floor of the three-tier pick tower consists of shelving dedicated to the storage of small items; pallets are stored below, on the ground and on the two remaining levels. Mesh decking is installed above the pallet locations on these two levels to provide additional carton storage.
A separate conveyor system now takes complete and partly-picked orders in totes away from the small items picking area before merging with the existing conveyor system, routed via existing picking zones, to arrive in the packing area. A new heavy duty spiral chute to enable fast track distribution around the warehouse was also installed.
SSI Schaefer subcontracted the in-rack sprinkler system to Tyco Fire & Integrated solutions, the electrical installation and data cabling was outsourced to EDI Services Ltd.
To minimise disruption to daily operations, SSI Schaefer meticulously planned the project to ensure Kiddicare remained fully operational throughout the entire period of installation.