A Case Study: Sunseeker, Poole, Dorset, UK


Couzens Storage Solutions have recently completed two new ‘whole remedy’ picking and storage systems for the world renowned boat manufacturer Sunseeker International (Boats) Limited.

Faced with an increased order book and subsequent increased manufacturing requirement, with limited storage facilities at two of their sites in Poole, Dorset. It was evident that the old stores just couldn’t cope with the foreseeable demand. A rationalisation was needed to improve efficiency, reduce manufacturing times and enhance product traceability plus provide increased security for the more valuable items that are a prominent feature of a luxury marque

 

A way forward was needed to overcome the difficulties.

 

Sunseeker contacted Keith Couzens, M.D. of Couzens Storage Solutions as a result of a referral from, not just one but, two of CSS customer’s who are Sunseeker suppliers.

Organizing the volume of parts spread over two existing stores in separate locations posed a complex logistical task for CSS. “The first project was started within limited space during a two week shut down, we  later also worked at night time and weekends to avoid compromising the critical kit picking activities, while Sunseeker were operational, which made things more complex for Sunseeker and ourselves, but working as a team alongside Sunseeker staff made the job that much easier, regular project meetings and re-organization of events and equipment when required, were essential to arrive at what we all set out to achieve” said Keith Couzens.

The two stores, measuring approximately 4000 square feet each, contained the parts used to construct and fit out a range of craft from the superb 34ft Super Hawk to the incredible 105ft Yacht. These parts varied in size and dimension from the smallest screw, through fridge’s, washing machines, pumps and timber posts to large sheets of very expensive and exclusive veneers.

 The first of the two sites at Poole is in Willis Way and now houses 2 Horizontal Carousels, a Modula, a Lift System and a Vertical Carousel.


The Horizontal carousel, CSS own design, is used for high value items like electrical goods, Satellite Systems, Audio and Television etc. It is totally enclosed for added security with 20 fully clad steel bays each measuring 2000mm high by 1000mm wide by 600mm deep. Each bay glides quietly and effortlessly on the existing floor surface via dual drives. This is a specific feature of the CSS designed unit, where the level of the floor is not critical and has no requirement for additional floor preparation. It also has a secure light curtain for improved safety with automatic doors to prevent entry whilst the unit is in motion. The Horizontals are linked to the clients host computer plus it contains its own onboard system for enhanced operational effectiveness and for added security the operation of all the carousels is controlled via password entry.


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The Vertical Carousel is equipped for small parts and houses over 4000 locations in bins of 3 varying sizes.
The Modula has 42 drawers of 4000mm long x 800mm deep, each drawer can take up to 750Kg. The Modula is specifically used for the heavier objects like bronze couplings, large bushes and zinc sacrificial anodes which can individually weigh over 20kgs. The Modula has a touch screen monitor and keyboard fitted, it is also equipped with a weight cell device displaying the total weight in each drawer as it is presented at the access port.
The Lift system is used to accumulate parts for production kits picked into 160 tote bins of 600 x 400 x 300mm ready for delivery to the production lines when required.

Also included in the contract was the construction of a Mezzanine floor along with pallet racking and long span warehouse shelving, specialist racking to house and protect veneers and doors plus the construction of an office on the Mezzanine floor complete with air-conditioning. Computer stations around the store positioned on the shelving were provided to give easy, convenient  access to data and picking lists for the store staff.


All computer hardware and software were supplied and links directly to the Sunseeker own host systems, located in the head office at West Quay Road, providing up to the minute management information for fast access and reduced processing time for store staff which is vital for control and production progression.


At New Quay Road, Poole the installation was similar in that it contained a Vertical Carousel for small parts, a Modula for large parts and a Lift System for accumulating the production kits. The Mezzanine floor also houses the stores office, along with long span racking and Computer systems. The Modula, Lift System and Vertical Carousel are 6500mm high again with storage bins in three different sizes to accommodate the variety of small parts.

It is this ability to provide whole solutions that sets Couzens Storage Solutions apart. Not only will they provide a simple shelving system or a single machine but they are there to advise and guide their customers with a completely unbiased and objective view helping them to make the right storage and handling decisions.
In fact Sunseeker Operations Manager, Geoff Kemp commented:

“The reason we chose Couzens Storage Solutions was that they had carried out similar installations for two of our key suppliers, both of whom we trust to give us an honest opinion. We carried out site visits and were impressed with what we saw. What impressed us most was the complete service that Couzens provide, everything from design through installation to after sales service. The range of products available both hardware and software was important and the belief that Keith Couzens would manage the project alongside our own team was also essential due to limitations on our own time. Sunseeker has not invested in storage solutions for some time and the growth of the company meant that an extensive stores was required with limited space. Couzens came up with the right design to match the number of parts, movements etc. and we gave them the go ahead. The stores are now benefiting the business in terms of kit accuracy, protection and security of stock and management of kits and shortages. Stock accuracy and rotation are essential to the smooth running of the business, the software helps us manage both of these requirements. The kit is reliable and looks state of the art. All in all a big success!!”

Comments like that reinforce the fact that Couzens Storage Solutions really do provide the complete storage solution.


For further details on how your business can benefit contact:  Couzens Storage Solutions Limited,

5 Heron Business Park, Eastman Way, Hemel Hempstead, Hertfordshire, HP2 7FW

Tel: 01442 250010 Fax: 01442 260602 

E-mail:info@CouzensSS.co.uk  or visit  the web site at www.verticalcarousel.co.uk


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