PERFECT ORDERS i PICK Order Manager and i PICK PERFECT solutions can provide distribution centers, warehouses and manufacturing kit production with perfect picks and orders using the latest technologies creating a seamless integration of “intelligent” products and services provided by Data Processing Services, Inc, an employee owned 44 year old company. PERFECT DELIVERY DPS has pioneered the latest picking and warehouse logistics technologies to ensure zero errors for perfect deliveries by using original designed pick to light (4 th generation graphical pop-in displays with no-wires, in a compact low voltage design). i PICK PERFECT solutions combine exclusive designed and built systems of the iPICK PERFECT products. PERFECT CONVEYANCE i PICK Order Management plus i PICK PERFECT SYSTEMS with i CONVEY PERFECT , i ZONE PERFECT , i WEIGH PERFECT and i DIVERT PERFECT , your distribution and manufacturing fulfillment systems are “ GREEN ” sources of additional bottom line earnings through improved picking speeds with accuracy and energy savings! Compact plug and play 24v DC modular high efficiency systems, built to be easy to assemble and manageable for retrofits extending reduced investments initial funding bringing extended life to your order fulfillment systems. The entire product line is designed to snap together, yet have the ruggedness of conventional non-green high voltage expensively installed 220 or 440v AC 3 phase electrical systems. EXPERIENCE DPS brings years of experience in designing and building automated warehouses. DPS has performed these services for large distribution companies such as The Source Interlink Periodical Fulfillment Division, The News Group, Anderson News, PMG International and Bill’s Dollar Stores as well as smaller wholesale distributors of Southern Wisconsin News, Rushmore News, Dakota News, and many others through out the world. DPS is fortunate to serve distribution system provisions in Europe, Canada, Mexico, the Caribbean, the Far East and the United States. Sketch by: Guy Buckmaster Specification: iPICK PERFECT SOLUTIONS Project: iPICK PERFECT Overview Product: iPICK PERFECT Date: 11/17/09 No: SPC-1-0 GO GREEN reduced carbon foot print, reduced energy consumption, longer life cycle
Sketch by: Guy Buckmaster Specification: iPICK PERFECT PICKING Project: iPICK PERFECT Overview Product: iPICK PERFECT Date: 11/17/09 No: SPC-2-0 i PICK ORDER MANAGER and i PICK PERFECT help bring energy efficient, labor efficient and safe worker ergonomics to order fulfillment. Space saving methodologies optimize warehouse space, and order fulfillment using techniques such as “optimum carton flow” to speed cartons through the pick process reducing errors and carton “held time” by each picker. Spreading the work load using features to balance the picking activity between pickers, category packing to speed merchandising at point of delivery, carton fill optimization to reduce number of cartons per delivery all combine to bring your company competitive edge abilities to achieve business success in challenging distribution logistic markets or in manufacturing increasing speed and accuracy of “kitting” for assembly. i PICK display-based pick and put to light system is one of the fastest, most efficient picking solutions available today! i PICK uses a large graphical LCD pick module with bright multiple color pick beacon button illuminating the pick BIN location guides the operator’s activity at the BIN location. The graphical display instructs pickers for bulk and loose picking from same location (i.e.: magazine bundles and loose copies pulled from same BIN location), plus instructs operator actions such as Close Box/Order Compete, No Pick, End of Pick, Do Not Advance, etc. Invoice and customer detail are sent to the display which helps operators verify they have made the correct actions. The i PICK LCD display is easy to install and maintain using the DPS innovative “snap-to-track” design. i PICK uses a four conductor embedded BUS integrated in the durable plastic extrusion which can be virtually mounted anywhere in flow racks or to static shelving. The embedded BUS design eliminates the problems associated with other designs. Data and power requirements travel the BUS with each module having BUS contacts that employ a “wiping” design that actually reseats each device with use. Each pick module is pre-assigned a unique serial number eliminating the need to set dip switches or configure elaborate setup address schemes. Maintenance associated and system outages associated with poor connections and shorted wiring is eliminated.
Sketch by: Guy Buckmaster Specification: QC Scales Project: iPICK PERFECT Overview Product: iPICK PERFECT Date: 11/17/09 No: SPC-1-0 TRACK i PICK Track is made of extruded plastic snap-tite front and back with four (4) embedded power and data wire conductors forming a BUS design. The innovative engineered BUS design track allows for “snap-in” of modules speeding installation and reducing maintenance and system down outages due to faulty wires and connections of older systems. GRAPHICAL DISPLAY i PICK display module is comprised of the LCD graphical display, display daughter board and the cover assembly. The cover assembly keypad has a translucent rubber switch over a tri-color LED that is mounted over the rigid extruded cover that joins the LCD display, daughter board and cover together forming the display module unit that “snaps” into the bottom track extrusion. DATA and POWER i PICK data and power (I/O module) module bring the power and data into the track, plus jumper the power and data from track to track. One (1) I/O boards is required at each connection of 5 foot track, plus at data or power entrance to the system. JUMPER BOARD TO JOIN TRACK i PICK data and power (JUMPER Board) bring the power and data into the track, plus jumper the power and data from track to track. One (1) I/O boards is required at each connection to join 10 foot track contiguously. At times this screw mounted board is used at data or power entrance to the system. DATA AMPLIER / REPEATER i PICK repeater/amplifier module handle data distribution activities through our the system, condition the data and extend the distances of data transmission. A minimum of one (1) repeater/amplifier board is required for each system. The data entrance to system is first linked up to a repeater/amplifier module from an I/O module. A repeater/amplifier module will handle a minimum of 100 displays. Repeater I/O Board I/O Board ROBUST COMPONENTS
Sketch by: Guy Buckmaster Specification: iPICK Display Messages Project: iPICK PERFECT Overview Product: iPICK PERFECT Date: 11/17/09 No: iPICK-1-0 Route, sequence, invoice, and account numbers displayed on ZONE MASTERS (beginning and end of a pick section/zone. Green LED can visually defines the ZONE area the picker is responsible Zone Master Display Instruction at BIN level is complete with indication of type pick – LOOSE ONLY of 21 copies. A Red LED button might tell the pick staff to expect loose copies only in this pick. Current Invoice and Customer shown 21 Loose Copy Pick Displayed To facilitate LOOSE and BUNDLE picks from same BIN location, an alternate color such as Purple is used with display indicating 21 loose and 4 bundles are to be picked. Current Invoice and Customer shown 21 Loose Copy & 4 Bundles Pick Displayed NO PICKS have dashes through the display and no LED is lit. This helps pick staff eliminate looking at these BINS speeding the pick staff to illuminated beacons only. No Picks Displayed CHECK PICKS instructs pick staff to find miss picks. By looking back at Zone, illuminated Buttons indicate what BIN was missed. Depressing button CONFIRMS pick. STOP – DO NOT ADVANCE to next pick as the picker in front of you is NOT FINISHED with current pick. This displays at ZONE MASTER when pick staff attempts to advance if you system setup indicates. END OF PICK displays to inform pick staff that the current container is completed. The display is illuminated with a Cyan colored display or other selected color indicating pick completion to picker. CLOSE BOX is messaged for action of closing the box and potentially sending to “quick out” path to quality control or pack out. Message may alternatively mean to indicate confirmation of “push-off” at end of Zone. White or alternate color LED button. No More Picks – Close Box Displayed No More Picks This Zone Displayed Do Not Advance to next Pick Displayed Check Picks Displayed i PICK – Intelligent illuminated paperless pick to light order management system The unique action directed multiple color LED with informative data or image lowers training effort and increases accuracy.
3.62” X 4.72” X 7.48” i PICK System Power Supply Input: 115/120v AC, 20 AMP Output: 15v DC, Adjustable, 50 AMP Sketch by: Guy Buckmaster Drawing: Power Supply (schematic) Project: iPICK PERFECT Overview Product: iPICK Date: 9/18/09 No: PS-1-0
Sketch by: Guy Buckmaster Specification: iCONVEY PERFECT Overview Project: iCONVEY PERFECT Overview Product: iCONVEY PERFECT Date: 11/17/09 No: SPC-3-0 i CONVEY PERFECT System Overview The i CONVEY PERFECT 24 volt DC conveying system is the ideal system for unit and package handling. It provides an extremely safe, modular, quiet and virtually maintenance free means of moving product within your facility. Basic Specifications Rated for 100lb per zone Up to 220 Feet Per Minute speeds. Operation Modes: Singulation, Train (slug), Normal Transport available on request. Bi-directional Rollers: Rollers can be reversed locally or via remote device. Incline and decline conveyor available in a variety of lengths. Standard BF widths: 14”, 15”, 16”, 17”, 22”, 24”, 28”, 30” Theory The i CONVEY PERFECT system is made up of modules. A module is defined as straights, curves, right angle transfers, merges and diverts. Programmable logic controllers control the modules. The modules themselves are further divided into “zones.” Product can accumulate within each zone if needed. The zones contain photoelectric sensors and reflectors. When the photoelectric beams are interrupted, this signals to the PLC that product is present in that zone. i ZONE PERFECT modules operate in singulate mode, or train mode. Normal transport mode is available if specified. In singulate mode, a product will not move into a zone until that zone is clear. In train (slug) mode, a product will move into a zone as the previous product is moving out of that zone. i DIVERT PERFECT provides the ability to divert product off of the main flow path. i MERGE PERFECT modules will merge product into a main flow path and can also transfer product off of the main flow to the right or left or both at a right angle. In all cases, the product has the option to continue down the main flow path bypassing the diverts and transfers. Data Processing Services, Inc. created i CONVEY PERFECT SYSTEMS with safety, modularity, quick low cost installation and low maintenance costs in mind. This “intelligent” system is the most practical system in the industry for moving totes, product assembly, packages and all unit-handling applications. i CONVEY PERFECT www.goDPS.com
Sketch by: Guy Buckmaster Specification: iCONVEY Components Project: iCONVEY PERFECT Overview Product: iCONVEY PERFECT Date: 11/17/09 No: SPC-4-0 Micro PLC management at “touch points” Easy install with plug and play 24v DC low voltage and data cable connections Safety First! No chains, belts, motorized gear boxes, heavy motors as the iCONVEY PERFECT conveyors use motorized 24v DC roller motors for a “pinch free environment” for your staff! No ear protection required 55 dba noise level (measured at one meter away w/background noise of 48 dba) Standard Frame Extruded aluminum side frame 7” X 1.625” Pre-punched hex holes on 1” centers Ability for 1”-2” hard skewing Supports Mounted on special mounting cavity running length of conveyor. No need for holes
Power Conveyor Profile i CONVEY PERFECT Power Roller and Gravity Roller Conveyor Profiles Gravity Roller Conveyor Profile Sketch by: Guy Buckmaster Drawing: Conveyor Profile Project: iCONVEY PERFECT Overview Product: iCONVEY PERFECT Date: 10/08/09 No: C-1-1
You can run up to 12 idlers off of one motorized roller
Required number of idler rollers
Photo electric eye sensor and sensor reflector in each zone of module
24v DC power supply needed per 16 motorized rollers
12” – 30” Modules : electrically slaved (see definition below.)
Less than 12” Modules : mechanically slaved (see definition below.)
Electrically slaved modules : (12” – 27”) Container accumulation cannot take place in an electrically slaved module. Controlled by an upstream PLC. Contains slaved drive roller, idler rollers and a motor control card. The motor control card is run off of a companion zone motor control card.
30” “one zone” electrically slaved module : Container accumulation can take place in a 30” slaved module.
Mechanically slaved modules : (less than 12”) Contains only idler rollers slaved via o-rings.
Sketch by: Guy Buckmaster Specification: iCONVEY Curves and 9” Slave Project: iCONVEY PERFECT Overview Product: iCONVEY PERFECT Date: 11/17/09 No: SPC-6-0 Curved Modules Standard : 30 degree, 45 degree, 60 degree, or 90 degree 90 Degree Curve Module (made up of two zones) : Components include PLC, motor control card, motorized roller with tapered sleeve, idler rollers with tapered sleeves and photo sensors and reflectors. 60 Degree Curve Module : “One Zone” Electrically slaved 45 Degree Curve Module : Electrically slaved 30 Degree Curve Module : Electrically slaved Container accumulation can take place in 90 degree and 60 degree curves. Example of 9” Mechanically Slaved Module
Sketch by: Guy Buckmaster Specification: Right Angle Transfer Project: iCONVEY PERFECT Overview Product: iCONVEY PERFECT Date: 11/17/09 No: SPC-7-0
Provides a means of “diverting” a container off of the main flow path into another flow or allowing the container to continue down its original flow path.
Each divert module contains 4 zones
Motor control card for each of the 9 motorized rollers
Motor brake relay
2 limit switches
Standard ways of controlling: Scanner or manual divert switch
Right Angle Transfer Modules (RAT)
RAT provides a means of moving containers off of the main flow path to the left or right
Containers may also pass through the RAT and continue down the main flow path
Components of RAT:
Three motor control cards for the following:
Roller Motor Control: moves a container onto or through the RAT
Pop-up assembly: moves a container to the right or left at a right angle.
Belt carriage assembly: connected to pop-up via drive belt.
Photo eyes and reflectors
Two limit switches (up and down)
Sketch by: Guy Buckmaster Specification: iQC PERFECT iWEIGH Project: iCONVEY PERFECT Overview Product: iCONVEY PERFECT Date: 11/17/09 No: SPC-8-0 Automated Weight Verification 100% Error Fee Orders! As cartons enter the beginning of the automated verification process on the 24 volt zone accumulation conveyor, they stage in zones before the in motion i WEIGH PERFECT scale. This guarantees a rapid and orderly process and insures that two cartons are never on the scale at the same time. The zone immediately before the i WEIGH PERFECT scale inducts cartons onto the scale once the current carton fully exits the zone. A Data Logic fixed position barcode scanner reads the pick label applied earlier in the process identifying the carton for i PICK PERFECT ORDER MANAGER .. This information is used to process the label based upon the information obtained by the system from our customers' Warehouse Management System (WMS) be it a DPS warehouse management system or another vendors. As the carton exits the scale, the label’s bar code data is sent to i PICK PERFECT ORDER MANAGER application so that the in motion i WEIGH PERFECT scale system process can perform a “check weight” on the cartons or totes using the i WEIGH feature embedded in the system against the "picked" order data coming from i PICK ORDER MANAGER or any other automated system with directed picking and order fulfillment process. i QC PERFECT Exception Process Some cartons or totes cannot be manifested automatically due to an error or special handling conditions. These cartons can be diverted to an exception station where an operator can manually process them. New designs have erred cartons sent back to the picker with correction detail available to the pick to light and/or optionally on a paper fix-ticket printout – invoices can be updated and deliveries are 100% accurate.
Sketch by: Guy Buckmaster Drawing: Quality Control Pictures Project: iPICK PERFECT Overview Product: iPICK Date: 9/21/09 No: QC Station Pics i PICK PERFECT QC Station Pictures (example of designs only)
Sketch by: Guy Buckmaster Drawing: Tote and Label Examples Project: iPICK PERFECT Overview Product: iPICK Date: 9/23/09 No: TL-1-1 i PICK PERFECT Tote and Tote Label Example of Tote Label Tote and Label orientation on conveyance
Sketch by: Guy Buckmaster Drawing: Tote Pick to Label Example Project: iPICK PERFECT Overview Product: iPICK PERFECT Date: 9/30/09 No: TL-2-1 i PICK PERFECT Tote with Pick to Tote Label Example Example i Pick to Tote Label Tote and Label orientation on conveyance
i PICK PERFECT System Labeling – Title iPICK Label: 6 Title capacity maximum i PICK Systems can provide for a bulk pick or low draw volume pick segregated from the i PICK display BIN’s enabling an alternative rapid invoice pick option where an agency might pick from pallet or a small title draw staged table area depending on volume and warehouse layout. These picks to container might also be late arrival titles and not put on the normal i PICK display line – yet can be married to order processing and weight pick quality control assurance in an i PICK PERFECT session. Bulk title pick areas often comprise 10 to 50 titles (depends on review of invoice draw and bundle size of supply). A review and calculation of average draw history to determine the optimum number of BIN pull slots can be performed to learn the best number of slots to provide. Low velocity titles might be those that are regional or special interest with a very low draw from supply and to fulfill retail orders. These titles may not make sense to stage to the i PICK display BIN, but rather pick to the small number of accounts and the small draws at a segregated pick area. In all of the above conditions, i PICK PERFECT can achieve agency goals of accuracy and efficiency. Sketch by: Guy Buckmaster Drawing: System iPICK Label Project: iPICK PERFECT Overview Product: iPICK PERFECT Date: 10/13/09 No: PL-1-1
Sketch by: Guy Buckmaster Drawing: Receiving Ultrascale II Project: iPICK PERFECT Overview Product: iSCALE PERFECT Ultrascale II Date: 9/23/09 No: US2-1-1 i PICK PERFECT Sonar Volume and Weight Entry Receiving Scale (Optional Purchase) Ultrascale II i SCALE PERFECT The i SCALE PERFECT Ultrascale II is designed to weigh and measure magazines or books in one easy step and transmitting the values to a receiving program. The compression plates will compress the magazines eliminating any errors that normally occur when measuring the thickness of a magazine with calipers. Transmitting these values directly to the receiving program also eliminates errors that can occur by keying in these values manually. Components Include (1) Compression Plate (2) Ultrasonic Device and Bracket Assy. (3) AC Power Cord (4) PC Interface Cable (5) 2 ea. ¼ x 1-1/2” Bolts Flat Washer & Lock Washer OPERATION IS EASY Turn On Power to scale with the On / Off Switch located on the lower left hand corner of scale. The scale will perform a short diagnostic test and establish a zero reference to the top of the compression plates. The screen should display the below detail after a few seconds. If the weight display does not show 0.000 press the ZERO key.