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Giới thiệu về Khách hàng
Tập đoàn Avery Dennison là thương hiệu toàn cầu nổi tiếng về vật liệu nhãn mác, bao bì và các giải pháp RFID. Nhà máy Avery Dennison tại KCN Long Hậu (Long An) có diện tích lên đến 28.000 m², đóng vai trò quan trọng trong chuỗi cung ứng các sản phẩm “Made in Vietnam” chất lượng cao ra thị trường quốc tế.
Thách thức: Lưu trữ hàng hóa dạng “Ống cuộn tròn”
Khác với các kho hàng thông thường sử dụng pallet phẳng, hàng hóa của Avery Dennison chủ yếu là các cuộn tem nhãn, decal, phụ liệu trang trí có hình dạng ống trụ tròn.
- Nguy cơ an toàn: Nếu đặt trực tiếp lên pallet hoặc mâm tole phẳng, các cuộn hàng sẽ dễ bị lăn, trượt, gây nguy hiểm cho người vận hành.
- Rủi ro hư hỏng: Bề mặt tem nhãn rất nhạy cảm. Việc chèn ép hoặc cố định không đúng cách sẽ làm trầy xước, móp méo sản phẩm, ảnh hưởng đến chất lượng in ấn sau này.
- Yêu cầu: Cần một giải pháp vừa tận dụng được chiều cao nhà kho (6.3m) vừa giữ cố định từng cuộn hàng một cách nhẹ nhàng nhưng chắc chắn.
Giải pháp Unirack: Kệ Selective tích hợp Máng đỡ (Cradle)
Sau khi khảo sát kỹ lưỡng quy cách sản phẩm, đội ngũ kỹ thuật Bảo Chánh – Unirack đã đưa ra phương án thiết kế “May đo” riêng cho Avery:
1. Hệ thống Máng đỡ (Cradle) thay thế mặt phẳng Thay vì dùng mâm tole phẳng, Unirack chế tạo các khung đỡ hình chữ nhật với mặt tole được uốn cong lõm xuống (dạng lòng máng).
- Cơ chế hoạt động: Độ cong của máng đỡ ôm trọn lấy đường kính của cuộn hàng.
- Tác dụng: Giữ cho cuộn hàng nằm yên tại vị trí trọng tâm, tuyệt đối không bị lăn khi có rung động. Bề mặt tole nhẵn mịn giúp sản phẩm không bị trầy xước khi trượt vào vị trí.
- Kích thước: Mỗi máng đỡ có kích thước Dài 1.500mm x Rộng 550mm, phù hợp với khổ hàng của Avery.
2. Kết cấu Kệ Selective cao tầng Để tối ưu hóa không gian nhà xưởng 28.000 m², hệ thống khung kệ được thiết kế vươn cao:
- Chiều cao kệ: 6.300mm, chia làm 7 tầng Beam. Điều này giúp tăng mật độ lưu trữ lên gấp 7 lần so với để sàn.
- Quy mô: Lắp đặt 03 dãy kệ siêu dài (32.76m/dãy) chạy dọc theo chiều dài kho.
Kết quả đạt được
Giải pháp sáng tạo này đã mang lại sự hài lòng tuyệt đối cho Avery Dennison:
- An toàn 100%: Loại bỏ hoàn toàn tình trạng hàng hóa bị lăn rơi khỏi kệ.
- Bảo vệ sản phẩm: Giảm thiểu tỷ lệ hàng lỗi do trầy xước bề mặt.
- Tiến độ thần tốc: Toàn bộ quá trình sản xuất máng đỡ đặc biệt và lắp đặt hoàn thiện chỉ diễn ra trong vòng 20 ngày, đáp ứng kịp thời ngày khánh thành nhà máy mới.
