In 2018, GBI delivered an Order Fulfillment solution for a government Pharmaceutical distribution.
Given the very nature of the business, the pharmaceutical industry is faced with challenges of cost and regulations. Pharmaceutical sortration carries a unique set of challenges.
The Challenge
The challenge was to fill orders rapidly and sequentially in very high volumes while maintaining order integrity. This automated solution begins with inventory being automatically inducted and pulled from pick walls, and ends as bagged orders, sorted into accumulation chutes (in sequence) to be shipped to local Pharmacies.
This workflow required immense planning, custom pick algorithms, and integration of multiple technologies including:
- two forms of automatic induction
- automatic label printing
- item and label verification and vision systems
- item bagging
- custom graphical user interfaces (GUI)
- item and order buffering
The Solution
The following describes highlights of the implemented solution in sequential order.
1. Induction
First, items are requested based upon order groupings determined in the data file. Product is picked from flow racks and inducted both manually and automatically to the sorter.
2. Product Labeling
Next, items are validated by a scanner array and are automatically labeled with the corresponding unique patient prescription while in transit on the sorter (label print and apply on-the-fly), or manually labeled prior to loading (based on product profiles).
3. Order Assembly
Labeled items are automatically combined on the sorter to fulfill orders, then diverted to operator stations to be assembled and bagged. Operators scan items and fill order bags from a semi-automated bagging machine.
4. Final Sort & Tote Completion
Orders are automatically sorted to stacking chutes to maintain sequence. Completed chutes contents are transferred to totes and brought to a tote completion station at which a shipping label and manifest are automatically printed.
5. Prepared for Shipping
Finally, the totes are labeled, sealed, and staged for delivery by group.
