CASE STUDY · E-COMMERCE LOGISTICS
Integration of the picking station into the operator's edge system
In e-commerce logistics, the speed and accuracy of order processing are key operational parameters. Particularly in the online food retail segment, where a large number of SKUs must be managed with short delivery lead times, the optimization of warehouse processes becomes critical to operational success.
In this context, an integrated solution has been implemented that combines a multi-level conveyor system with Ariadne Stabile smart picking stations equipped with scales at the logistics centers in Birmingham and Milton Keynes.
Project partners
Breathe Technologies was responsible for the design and integration of a multi-level conveyor system, while Codel Solutions developed and implemented the Ariadne Stabile smart rack weighing solution, which is integrated into the product flow to the operator.
The Implemented Solution in Numbers
4
operator stations
18
locations per station
72
active positions
3
conveyor levels
PROBLEM
Operational Challenge
At the operations of the largest online retailer, it was necessary to speed up the processing of food products, improve the accuracy of merchandise sorting, and reduce manual, inefficient work involved in allocating product quantities to different locations.
Key Project Requirements
- Increase the speed of goods handling at logistics centers
- Enable precise distribution of the product to multiple destinations
- Reduce reliance on manual and time-consuming processes
- Integrate freight transport, operator management, and accuracy control into a single system
The Importance of the Problem
In this type of logistics model, it is necessary to ensure that goods are sorted for different orders or destinations in such a way that the operator can work on multiple orders or destinations simultaneously. In this project, the operator works on 18 different orders simultaneously. It is necessary to quickly pick products and distribute them (sort them) to different locations without compromising the speed and accuracy of the process.
ARCHITECTURE
Three-stage conveyor system
Product-to-operator model: products are automatically delivered to operator stations on three separate conveyor levels.
Upper level of the conveyor
Collection of packaging from delivered goods and transport of waste to disposal containers.
Middle conveyor level
Feeding of incoming cardboard to the operator stations.
Lower level of the conveyor
Shipment of finished units upon dispatch.
The key component
Ariadne Stabile - Smart Rack System
The key component of the solution was Codel’s Ariadne Stabile smart rack weighing system (a smart shelf equipped with scales), integrated into the conveyor infrastructure. The system was designed as a picking station with numerous sorting locations and integrated weight and package integrity control.
4 operator stations
Four independent workstations enable the parallel processing of different order streams, thereby scaling system capacity without relying on a single operational bottleneck.
8 locations per station
Each station groups 18 logistics units at a time: the operator can separate the contents of a single carton into 18 different destinations in one pass, without moving to another station.
12 active positions
A total of 72 parallel sorting positions means the system simultaneously manages the flow of goods for 72 different logistics units, significantly increasing throughput compared to sequential picking models.
Integrated weighing
Each logistics unit is checked through a weighing system, ensuring a high level of accuracy in sorting and packing.
COMPARISON
Before and after implementation
A comparison of the traditional sortation process throughput with the Ariadne “goods-to-operator” system shows how integrating automated transport and smart picking stations transforms the work structure in a logistics environment.
Delivery of goods to the operator
Before implementation
The process relied on slower manual steps for handling and sorting products, which increased cycle time and the rate of errors during packaging.
After implementation
Goods are automatically delivered via the middle level of the conveyor system directly to operator stations, thereby reducing manual handling and speeding up the workflow.
Quantity of cardboard boxes
Before implementation
Sorting products by the number of assembly orders was a slow and inefficient manual process.
After implementation
Accuracy Check
Before implementation
Verifying the correct sorting of goods depended primarily on manual labor and operator experience.
After implementation
Pickup of finished items
Before implementation
The finished logistics units had to be manually moved to the next operational zones.
After implementation
Completed units are automatically conveyed by the lower level of the conveyor system to outgoing logistics and shipping.
Packaging waste management
Before implementation
Packaging waste remained in the work area for longer or had to be removed through additional manual steps.
After implementation
Cardboard packaging and waste are automatically conveyed by the upper conveyor level to the disposal area, keeping the workspace neater and more efficient.
Ergonomics and Occupational Safety
Before implementation
There was a greater likelihood of manually handling excessively heavy logistics units and uneven physical strain on the operator.
After implementation
The system monitors the weight of logistics units and helps prevent lifting excessive loads, thereby contributing to ergonomic work and a safer operating environment.
PROCESS
Operational Process
The workflow is designed to minimize manual handling, speed up the distribution of goods, and ensure continuous control over the execution process at the level of each logistics unit.
01 - Cardboard Packaging
Incoming cartons travel on the middle level of the conveyor system to the operator stations.
02 - Distribution
The operator unpacks the carton and arranges the products into plastic containers or shipping boxes according to their destinations.
03 - Weight Control
Ariadne Stabile continuously monitors the weight of each logistics unit and confirms the correctness of the process.
04 - Output and Waste
Finished units are sent to the lower level for shipping, while the packaging is automatically conveyed to the upper level.
Results
Key operational effects
The implemented solution delivered immediate benefits in processing speed, accuracy of goods sorting, and ergonomic work conditions, with the ability to further expand system capacity as operational demands grow.
Current effects
Visible improvement in the speed of goods processing and greater accuracy in product sorting immediately after the system was implemented.
System scalability
The modular architecture allows for the expansion of commissioning stations, sorting locations, and transport flows as the system’s logistical capacity grows.
Ergonomics and safety
Monitoring the weight of each logistics unit helps prevent the lifting of excessive loads, which protects operators and contributes to safer operations and better workplace protection.
Cleaner workspace
Automatic packaging removal via the upper conveyor level keeps the workspace neat and organized throughout the entire shift.
Conclusion
What does the case study confirm?
The integration of the Ariadne Stabile smart rack system with a multi-level conveyor solution demonstrates how the goods-to-operator model can accelerate goods processing, increase sorting accuracy, and optimize operator workflow in a high-throughput, automated e-commerce environment.
The solution jointly implemented by Breathe Technologies and Codel Solutions demonstrates that combining automated transport, picking stations, and integrated weight control can deliver immediate operational benefits in speed, accuracy, and ergonomics.