Automation proves to be the best medicine for pharmaceutical manufacturer Teva

Teva is one of the top 20 global pharmaceutical companies and is the UK's leading generic manufacturer, making products for which the original patent has expired. The new centre, designed by SSI Schaefer, is not only meeting Teva's current needs more efficiently but, crucially, offers sufficient capacity for the company's anticipated growth. SSI Schaefer designed and installed the internal layout of the facility, introducing automation systems throughout the warehouse operation – an automated storage and retrieval system (ASRS) with three cranes and 3,500 single deep storage locations was installed, alongside pallet racking complete with 21,000 storage locations, a pallet conveyor system, tote conveyors and a pick-by-light system with 13 pick stations and 910 locations. The whole operation is monitored and managed by SSI Schaefer's Convey warehouse control system. Items are picked using three options: full pallets are 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 methods depend on the size of the order and are determined by the warehouse management system, which also calculates carton numbers and sizes per order. Teva's operations manager, JP Bednarek, said: "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 allows us to handle immediate needs but will also accommodate future growth in the business."