Coca-Cola

Coca-Cola case study.

Quick Facts

GOAL
Optimize logistics network to enable quicker response
size
253,500 Sq.Ft.
THROUGHPUT
85 Million Cases Annually
products handled
Cases and Pallets of Soft Drinks
OUTCOME
Consolidated mixed lot shipments and improved loading/unloading time by 70%

Coca-Cola is the 3rd largest beverage company in the world.

On May 8, 1886, Dr. John Pemberton served the world’s first Coca-Cola at Jacobs' Pharmacy in Atlanta, Ga. From that one iconic drink, Coca-Cola has evolved into a total beverage company. More than 1.9 billion servings of their drinks are enjoyed in more than 200 countries each day. And it’s the 700,000 individuals employed by The Coca-Cola Company and 225+ bottling partners that help to deliver refreshment across the globe.

Challenge

To optimize their logistics network to enable a quicker response to changing market conditions and diversifying consumer needs, seeking to create a high-quality, low-cost, and stable supply chain through end-to-end material handling automation.

Solution

To optimize their logistics network to enable a quicker response to changing market conditions and diversifying consumer needs, seeking to create a high-quality, low-cost, and stable supply chain through end-to-end material handling automation. Product enters the warehouse either directly from the on-site plant or through delivery trucks carrying goods from other production sites.  Daifuku installed (8) robotic layer depalletizers to break pallets (same SKU) down one layer at a time, with each layer then broken down further into individual cases and transported from the third to second floor where individual cases are temporarily stored in the Shuttle Rack M until ready to be palletized (mixed SKUs). The Shuttle boasts 462 shuttle vehicles and 74,000 storage locations (cases).  The shuttle feeds one of 21 palletizing robots on the same floor. The robots quickly pick up cases, plastic totes, and crates of varying shapes and sizes and load them into mixed load pallets. When the mixed load pallets are completed, they are transported to a wrapping machine and then sent to the shipping area.  Forty-two Sortation Transfer Vehicles (STVs) were installed to deliver pallets ready for shipping to the staging area where five stacker cranes transport pallets to the appropriate staging lane.

Pallets containing incoming products needing to be shipped urgently, can be loaded into the AS/RS through the first floor. The staging lanes utilize multi-stage inclined flow shelves that can accommodate one truck load for each destination. Two Roll-in/Roll-out (RORO) stations fully automate the loading and unloading of truck loads in batches. Using forklifts takes about 60 mins to load one truck, where the RORO can achieve this in only 20 minutes. The automation in this DC enabled Coca-Cola to integrate the processes of 24 smaller Coca-Cola sites and incorporates all their product storing, sorting, picking, and other logistics processes under one roof.

Outcome

Along with delivering improved efficiency across logistics operations, the facility is building a network that achieves end-to-end product deliveries in a timely manner from manufacturing through to clients and vending machines.  Conventionally, mixed lots had to be shipped out via several Coca-Cola facilities, but by installing the palletizing robots, the company was able consolidate this task into the Saitama Mega DC, which has led to a significant increase in efficiency.  In addition, automated truck loading and unloading reduced related work time to one third.

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