teva THE WORLD‘S LEADING GENERIC PHARMACEUTICAL DISTRIBUTION CENTRE Case Study Teva UK Limited, Castleford United Kingdom CASE STUDY Teva UK Limited Operating in the UK for 75 years, Teva UK Limited is among the top 20 pharmaceutical companies in the world, and undoubtedly the largest in generic products. The company aims to have the widest product portfolio in the UK pharmaceutical industry and to offer the advantages of speed, choice, quality and cost to a very broad nationwide customer base. Full case pick conveyor system Consolidation of sorted order cartons by destination Pallet conveyor feed to ASRS Order dispatch sort lane Order item checking and packing Teva UK LIMITED Project profile As a manufacturer and distributor Teva UK Limited supplies medicines to pharmacies and hospitals, from painkillers to antibiotics, and cholesterol reducers to lifesaving medicines to fight cancer. Their specialities are generic medicines – which are usually medicines whose patents have expired – and respiratory medicines, especially inhalers to relieve the symptoms of asthma. They offer generic products in almost all major therapeutic areas in a variety of dosage forms, from tablets and capsules to ointments, creams, liquids and injectables. Teva UK Limited supplies more packs of medicine to the UK’s National Health Service than any other supplier and the company is part of Teva Pharmaceutical Industries Ltd (NASDAQ: TEVA) which has 40,000 employees based around the world. Teva‘s objectives were to increase storage capacity, improve pick accuracy, efficiency and customer service and to reduce the labour overhead within the distribution operation. The design and build of a new distribution centre and the introduction of automation to the process were seen as being key to achieving these objectives as well as providing the capacity to accommodate future business growth. Pallet racking Schaefer pallet crane SSI SchAEfer solution Teva UK Limited despatches over 4 million items per day and to achieve this three different modes of picking are employed. These include full pallets selected from the Pallet Racking, full cartons from the ASRS and single items from the Pick by Light system. Ergonomically designed pick stations equipped with hydraulic pallet lifting devices have been installed to help operators. Despatch method is dependent upon order size and is determined by the warehouse management system, which also executes volumetric calculations to determine carton numbers and sizes per order. The picking system also allows its operators to record product batch changes and shipping cartons undergo automatic weight checks and in-line shipping label application before being sorted to shipping destination lanes prior to despatch. As the UK‘s leading generics manufacturer they are constantly striving to improve their service and product offer and, in order to maintain this momentum, the introduction of the automated materials handling and storage systems installed by SSI Schaefer has been regarded as vital to the company’s continued success. Three different Modes of Picking Single item Picking area – Pick by Light Full Cartons picking from the ASRS The replenishment for the Pick by Light-equipped Flow Racks either comes from the ASRS or the Pallet Racking area. Pick by Light supports picking of fast and medium moving products. The display-controlled system guides pickers with exact position indication and quantity to the relevant storage location. Due to a special function it is possible to request product replenishment in advance directly from the Pick by Light workstation by the push of a button – via the warehouse. The SSI Schaefer Pick by Light system allowed Teva UK Limited to optimise its picking process and thereby strongly increased its picking efficiency and accuracy. The order cartons are then directed to the Handling systems area. Automatic Storage and Retrieval Systems (ASRS) are an important part of a cost effective logistic chain and allows optimised warehousing with quick transport of material and short access times. The ASRS implemented in the Teva UK Limited facility consists of 3 single mast units and transfers goods coming from the pallet racking zone to the handling systems area. This highly dynamic pallet storing system allows the storage of pallets single- or double-deep. Fast moving full cartons are stored palletised in the ASRS for quick access and retrieval. Full Pallets Picking from the Pallet Racking All other products are stored in the Pallet Racking zone. Fully picked pallets go straight from the pallet racking area to the Shipping department. CUSTOMER STATEMENT SSI Schaefer were able to visualise our needs from the outset focussing on our ultimate goal – to improve upon on our customer service levels and product offering. Our new fully automated storage and distribution facility has enabled us to easily reduce our labour overheads by moving from a three-shift operation to two shifts. Perhaps most importantly, the increased storage capacity has allowed us to handle immediate needs but will also accommodate future growth in the business. CASE STUDY Teva UK Limited Facts and Figures System key figures Warehouse Size in m2 13,000 Picking system Size in m2 9,000 Products (SKU’s) 840 Totes/day 8,500 Carton/day Degree of Automation (%) 55% Working Hours/Day 16 hours Number of Shifts/Day 2 Scope of supply and services Conveying system Pallet Conveyor Roller, chain and turntables and shuttle car Tote Convenyor Belt, roller, 78 sort lanes Waste Conveyor Picking systems Pick by Light Carton live storage Automated Storage and Retrieval System (ASRS) 13 pick stations 910 locations Number of cranes 3 Number of locations 3,500 (single deep) Load units of Pallets 1200 x 1000 mm Goods-to-man carton picking system with hydraulic pallet lifts System components Print and apply labelling system workstations Pallet Racking Footprint 125 x 53 metres Height 12 metres Storage locations 21,000 Software solution Warehouse Control System (WCS) SSI Schaefer Convey Nr. 251010uk. © SSI Schaefer Graz Printed in Austria. We assume no responsibility for printing errors. SSI SCHAEFER LTD 83/84 Livingstone Road Andover, SP10 5QZ Phone: +44/12 64/38 66 00 Fax: +44/12 64/38 66 11 solutions@ssi-schaefer.co.uk www.ssi-schaefer.co.uk SSI Schäfer Noell GmbH i_Park Klingholz 18/19 D-97232 Giebelstadt Tel. +49/93 34/979-0 Fax +49/93 34/979-100 info@ssi-schaefer-noell.com www.ssi-schaefer-noell.com SSI Schäfer Peem GmbH Fischeraustraße 27 A-8051 Graz Tel. +43/316/60 96-0 Fax +43/316/60 96-457 sales@ssi-schaefer-peem.com www.ssi-schaefer.com