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Accu-Sort Systems Help Distribution Center Achieve 99.997 Percent Accuracy and Increased Capacity

Friday, June 19, 2009

PHILADELPHIA, PA — Accu-Sort® Systems, Inc. announced that newly installed bar code scanning, labeling and sortation systems are delivering higher throughput and 99.997 percent accuracy at a distribution center that handles retail software and entertainment discs as well as computer hardware such as keyboards and game consoles. The facility shattered its old single-day ship record by 63 percent and now ships 99.997 percent of units accurately, on time, and without split shipments.

"The improvements in accuracy and throughput have been revolutionary," one company executive said. "We had to add a third decimal place to keep our statistics from rounding to 100 percent."

The company's revamp of operations, warehouse and distribution functions included switching to very narrow aisles and pick-to-light. According to an engineering executive at the company, the project enabled the distribution center to expand capacity as needed to accommodate seasonal peaks and support a growing business in 3rd party logistics.

The Accu-Sort systems integration team designed and developed a complementary solution to improve the efficiency of the facility. The heart of the system is an Accu-Sort FAST Label® System. This solution is a real-time control system that provides increased throughput and shipment accuracy. The FAST Label® application receives the bar code data from a high-performance Accu-Sort scan tunnel, communicates with the host system, and prints and applies the correct shipping label on the appropriate carton. As part of the system, an Accu-Sort AXIOM™ laser bar code reader is positioned after the labeler to verify the combination of the carton bar code and shipping label. FAST Label provides the destination information to the conveyor control system ensuring that each carton is diverted to its correct destination. The system software utilizes the carton volume to determine whether a carton will fit on the current pallet or if a new pallet must be started.
The solution leverages the precision of a camera-based scan tunnel configured with five Accu-Sort AccuVision® AV4000 camera bar code readers and an Accu-Sort DM3500 dimensioner. The Accu-Sort team chose camera technology over laser-based scanners because of the need to read small bar codes moving at high belt speeds. The DM3500 is used both to focus the camera on the varying carton sizes and to obtain the volume of the cartons.

"Overall, our customers' goal is to get the right product to the right customer at the right time," said Pratap Chakravarthy, director of marketing with Accu Sort Systems. "That is central to our customers' businesses, and these systems give our customers a competitive advantage."

For more information about Accu-Sort bar-code equipment and systems integration, visit

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