Projects

Ngahuia Group achieves efficient national distribution with automated sorting solution

Facing a labour-intensive dispatch process, Ngahuia Group partnered with Dyno to implement a high-speed, high-accuracy automated sorting system, transforming their distribution to Number One Shoes + Hannahs stores.

THE CHALLENGE

To address significant inefficiencies in their dispatch operations for Number One Shoes and Hannahs stores nationwide, Ngahuia Group sought a comprehensive automation solution for their Whakatu distribution centre.

Dyno collaborated closely with Ngahuia Group to design and implement an intelligent sorting system that tackled labour-intensive processes, space limitations, and strict performance targets.

Dispatching products to fifty-one Number One Shoes + Hannahs stores from Ngahuia Group’s distribution centre was a highly manual and time-consuming task. Nick Payne, the DC Manager, identified critical areas needing improvement. The key objectives were to automate the sorting process to each store with an accuracy exceeding 99% and to achieve a throughput of 3000 sorts per hour.

Adding to the complexity were the constraints of the available space within the distribution centre and a specific project delivery timeframe that needed to be met. Dyno undertook a thorough discovery process to understand all the critical factors, including the existing workflow, space limitations, and the urgency of the project. This detailed analysis was crucial in determining the optimal design direction for the automated sorting system.

The Solution

Drawing upon the insights gained during the discovery phase, Dyno engineered a tailored sorting system designed to meet Ngahuia Group's precise requirements.

The system functions by scanning each product destined for the stores and automatically diverting it to the designated lane for that specific retail location. Once a sufficient number of items accumulate in a lane, they are manually palletised for dispatch.

A vital element of the solution was the seamless integration with Ngahuia Group’s existing Warehouse Management System (WMS). This integration ensures that the sorting system operates using accurate, real-time product data, including SKUs and sequencing information, guaranteeing correct and timely order fulfilment. The strong partnership between Dyno Ltd and Nick Payne’s team at Ngahuia Group was instrumental throughout the project, with Ngahuia Group providing excellent information and support.

The Result

Dyno facilitates significant operational improvement for EBOS

This project underscores Dyno Ltd’s expertise in developing and implementing sophisticated automated sorting solutions that address specific operational challenges and deliver tangible improvements in efficiency, accuracy, and throughput. By working in close partnership with Ngahuia Group, Dyno facilitated a significant upgrade to their national distribution capabilities.
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The implementation of the automated sorting system has delivered substantial benefits to Ngahuia Group’s distribution operations.

  • Significantly enhanced efficiency

    Automating the sorting process has dramatically reduced manual labour in the dispatch area.

  • Exceptional accuracy

    The system consistently achieves a sorting accuracy rate of over 99%, minimising mis-shipments to stores.

  • High throughput capacity

    With a capacity of 3000 sorts per hour, the system efficiently handles the demands of national distribution.

  • Effective space utilisation

    The designed system effectively operates within the previously constrained space.

  • Seamless WMS integration

    Real-time data exchange with the WMS ensures accurate and up-to-date sorting.

  • Strong collaborative partnership

    The excellent collaboration with the Ngahuia Group team was key to the project’s success.

Products

Dyno products used in this project

Products