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We have been processing steel for over 25 years

Address

4517 Washington Ave.
Manchester, Kentucky 39495

Phone

+1 800 123 456 789
+1 800 123 456 780

Email

[email protected] [email protected]
The System
HomeThe System
Functional Technical Description of the Superfilment™ System

Stage 1: Pallet Distribution

1. All fulfillment active product SKUs are received on trailers on a just-in-time basis. With an average window of 20 hours between pallet exchanges it will be possible to combine many product SKU’s from an individual product supplier.

2. Trailers are unloaded by AGVs and the pallets are delivered to their appropriate SKU Rack.
3. As outlined every SKU Pallet configuration will be designed specifically for use in the Superfilment Center. The design will maximize efficiency the corrugated board used in the pallet’s configuration. The SKU Pallet is specifically designed to be Robot friendly for each of attributes of the SKU. Each SKU Pallet will be designed to be making ready the pallet for the de-palletization process.
4. Filled SKU Pallets will be delivered to a Pallet staging position Pallet Rack by the AGVs.
5. At each SKU Rack Position up to 10 Filled Pallets will be staged. On average a filled SKU Pallet will depalletize every 8 hours. On Average10 Staged SKU Pallets will be depalletized every 20 hours requiring SKU Pallet replenishment every 20 – 24 hours.
6. At the robot Depalletizing station the Robot will cut and dispose of the pallet straps and pick and dispose of the pallet cap and slip sheets if necessary.
7. Empty SKU Pallets will be removed from the SKU Pallet Rack by the AGV after the AGV has placed the filled SKU Pallet in the SKU Pallet Rack. Empty Pallets will be placed into an empty pallet staging area for recycling of the pallets.

Stage 2: Tote Staging, Tote Robot Loading

1. A tote distribution system consisting of approximately 3,500 totes and over 15,000 feet of conveyor will control the tote operation. The SmartTotes will maintain a unique electronic identifier that will maintained in the control system. Whole and partial orders will be designated to individual SmartTotes. The 3,500 SmartTotes form a closed loop system. Each tote will be assigned a UPC that will define all aspects of the order requirement. Each tote could be a complete or partial order. This data is used to determine the exact route and loading sequence for each tote.
2. SmartTote fulfillment starts with insertion of a bag into the tote. Empty totes are received on the return conveyor from the Transrector tote discharge conveyors. Exhibit 6 outlines the Bag Inserting and cuffing machines currently in use throughout the packaging industry.
3. Upon arrival of the SmartTote from the Bag Inserter stations at one of the SKU load stations the SmartTote will be elevated to an appropriate SmartTote loading station.
4. At the individual Smart Tote loading station the SKU Robot will pick the product from the pallet and place the product into the SmartTote. Once the appropriate number of order components have been loaded into the SmartTote will be returned to transport conveyor and travel to its next SKU Load Station. This process will continue until the Customer order or partial order is completed.

Stage 3: Corrugated Packaging Removal and Pallet Retrieval

1. As the SKU Robot depalletizes the products into the SmartTotes the corrugated shippers are emptied. Empty individual product corrugated shippers are picked by the SKU robot and dropped to a corrugated material recycling conveyor located in the center of the SKU Racking System.
2. The corrugated material recycling conveyor will transport all of the disposed material to a Corrugated Compacting Machine.
3. AGV will pick the bundles and position them into a recycling trailer for delivery to the recycling station
4. At the individual Smart Tote loading station the SKU Robot will pick the product from the pallet and place the product into the SmartTote. Once the appropriate number of order components have been loaded into the SmartTote will be returned to transport conveyor and travel to its next SKU Load Station. This process will continue until the Customer order or partial order is completed.

Stage 4: Case Packing and Package Preparation

1. Completed customer orders will be conveyed to Transrector Pack stations. The SmartTote with data on all dimensional and weight information for each component in the customer order. The Order Information data is used to select the optimized case size from then table of available case sizes. The SmartTote will be directed to the appropriate Transrector and will be cued for case loading. The case loading operator will un-cuff the bag from the SmartTote and load the bag with the customer order contents appropriate sized case. The operator will ensure optimum load of the bag and product in the case. Associates will be responsible for organizing the ordered components in the case during the case loading process. Dunnage is not required due to box right sizing and the excess material in the bag acting as dunnage when required.
2. Bar Code and Shipping Labels will be automatically applied to the erected case at the top closing station.
3. The Sealed and labeled Case will be Check Weighted to insure Customer Order accuracy.
4. Dunnage if necessary can be automatically sized and dispensed into the empty case prior to the manual loading station.
5. Bar Code Labels are automatically applied to the erected case at the top closing station.
6. The Order Information data is used to select Heavy and Fragile labels as required and can be automatically applied when necessary.

Stage 5: Delivery Route Distribution and Van Loading

1. The verified Shipping case will be directed to one of 70 Case Accumulation Stations as determined by the Delivery Route of the package. The Case Accumulation Stations are directly adjacent to the appropriate Delivery Van loading Position.
2. At Order Fulfillment Capacity of 7,000 orders per hour, every hour 70 Van Delivery Drivers will start an 8 hour shift. The Van Driver will start the shift by packing all of the Cases for the designated route into the route’s designated van. On average between 75 and 150 cases representing the Customer Orders will be loaded into the Van by the Van Drive. Once the loading operation is completed the Van Driver will distribute the products to the customer using traditional delivery Smart Phone applications
3. The Delivery Van Distribution Model

Superfilment™ Center

As outlined in the Simulation and narrative there are no technological barriers to executing a fully Autonomous Supermarket Online Fulfillment System. The following video makes a sales pitch for the Superfilment™ Program: https://youtu.be/F29ilhzeKIk

Fully functional Superfilment™  as outlined  are estimated to have the ability to effectively provide a large metropolitan city fulfill over 1,000,000 online orders per week.  This extraordinary Fulfillment achievement would be delivered consistently with less than 1,700 fulltime delivery contractors,  less than 50 FC Operators, less than 20 machine and building maintenance personnel and less than 30 IT and administrative personnel in a 24/7 operation. All of the Superfilment™ technology and machinery presented in the Superfilment™ Model described herein is technology that is being currently being used in one form or another in various Fulfillment operations throughout the world. All components outlined in the Superfilment™ Model are used throughout many industries and are proven to be effective and reliable in performing the automated tasks described in the model. There is on technology employed here that is not already developed, proven and effective. The only thing that is unique about the Superfilment™ Model in this Prospectus is how the Model is assembled and integrated. The Lights-Out Fulfillment Center Model will not only revolutionize Fulfillment Center operations but it will revolutionize the Retail Industry as we know it today. The Superfilment™ is the world’s one and only “No Touch” Fulfillment Distribution system. At no point in a Superfilment™ will a human being ever need to touch any of the 2,000 to 4,000 products being distributed. The Superfilment™ Model will never replace Amazon’s wildly successful “The Everything Store” model with a 1 million SKUs. However as the Superfilment™ Model will provide same day delivery of the world’s 10,000 – 20,000 of most widely used daily necessities of life. The Covid-19 crisis will only advance the ultimate need for the successful implementation of the Superfilment™ Model. The estimated Capital Cost associated with a full Scale Superfilment™ full scale production model is outlined in Exhibit 7.

 

The following video simulation outlines the various features of Superfilment™ video: