Introduction: Beijing Xiaocan Tea Industry Co., Ltd. was founded in 2014 and is a modern tea merchant that emerged under the Internet thinking and experience economy. Small pot tea integrates the advantageous resources of the Chinese tea industry with innovative ideas and highly creative techniques, and collaborates with ten tea masters from six major tea categories to adhere to the principles of origin raw materials, master craftsmanship, and master supervision. It also innovates small pot nitrogen filling and preservation technology, jointly creating a master level Chinese tea and setting standards for good Chinese tea through innovative craftsmanship; Using innovative products as a benchmark for high-end tea trees in China.

        Mount Huangshan Tiny Pot Tea Industry Co., Ltd., a small pot tea production center located in the Huihua Cultural Industrial Park, Meilin Avenue, Economic Development Zone, Mount Huangshan City, Anhui Province, was established in 2016. In the same year, the first fully automated aluminum can filling production line in the tea industry independently developed by the small pot tea industry was put into use. In 2017, Mount Huangshan Super Factory, the industry's first intelligent chemical plant with a total investment of 1.5 billion yuan, officially started. With the rapid development of enterprises, Xiaocan Tea became a well-known Chinese tea brand with a retail sales volume of over 2 billion yuan in 2018.

        1 Project Introduction

The total investment of the small pot tea Mount Huangshan Super Factory is 1.5 billion yuan, with a total floor area of 321 mu and a main building area of nearly 30000 square meters; Mainly composed of automated production workshops and intelligent storage logistics centers, achieving full automation of production, storage, and distribution. Mainly meeting the delivery of two business forms of small can tea, B2B and B2C. With a designed inventory of over 500000 pieces (boxes) and an average daily delivery volume of over 8000 pieces, it is a world-class tea production and distribution demonstration factory with a daily delivery volume of over 30000 pieces during peak periods.

       2 Overall layout

The intelligent chemical plant consists of four main buildings, including a production workshop, an intelligent warehouse, an office building, and an employee dormitory. The production workshop and the intelligent warehouse are connected through a corridor. The intelligent warehouse is divided into two three-dimensional storage areas (one of which is implemented in Phase II) and one flat storage area. Each three-dimensional storage area has a building height of 23.7 meters and a building area of about 2000 square meters. It is divided into room temperature storage and low temperature storage. A total of 5 lanes of AS/RS three-dimensional storage are designed, with 14000 pallet storage spaces; The Pingku area covers an area of 6700 square meters, with a building height of 23 meters. It is divided into two floors. The first floor is mainly the shipping area and cold storage area, while the second floor is the dismantling and picking area, production and distribution area, and e-commerce distribution area. A four-way shuttle car "goods to people" picking system is designed, divided into two areas of room temperature and low temperature, with a total of 34500 box storage spaces, 5 goods to people picking stations, 3 box changing workstations, and 21 rechecking and packaging platforms. In addition, The production workshop is equipped with a buffer area stored in a four-way shuttle car, and a buffer area of 529 box units is designed.

       3 Main Operation Procedures

        1. Warehousing workflow

        The warehousing operations of intelligent chemical plants are divided into two categories: full pallet storage and full box storage.

        1) Whole pallet storage

        It is mainly divided into receiving whole palletized storage and production whole palletized storage.

        Receiving and palletizing storage: The goods are manually palletized from the receiving area. After the acceptance group is completed, the forklift will place the entire pallet of goods at the entrance of the AS/RS storage conveyor. After completing the weighing, barcode, and peripheral dimension checks, they will automatically enter the AS/RS system for storage. Part of the produced goods can be automatically stored in the AS/RS system after completing the same warehousing process at the entrance of the AS/RS warehouse conveyor on the second floor.

        Production whole pallet storage: The whole box products produced by the automatic production system are transported to the designated box conveyor line entrance through an AGV automatic transport trolley at the unloading port of the production line, transported by a hoist and box conveyor line to the mechanical arm stacking area. After completing a pallet by the mechanical arm stacking, they are transported into the AS/RS system for storage through the annular trolley and tray conveyor line. picture

        2) Full container storage

        Mainly divided into destacking full container storage and production full container storage.

        Unstacking and full container storage: When raw materials and packaging materials are needed in the production workshop, they are called for through the MES system. The WMS system receives information and will palletize and ship goods from the AS/RS three-dimensional warehouse. The goods are then transported to the robotic destacking area through pallet conveyor lines and circular trolleys for robotic destacking. As required, a portion of the destacked goods arrive at the designated unloading port in the production workshop through the box conveyor line, and then transported to the automatic production line crossing through AGV. The remaining unstacked full box goods are transported through a box conveyor line and stored in the four-way shuttle system.

        Production full box storage: The full box products produced by the automatic production system are transported to the designated box conveyor line entrance through an AGV automatic transport trolley at the unloading port of the production line, and then transported by a hoist and box conveyor line to the four-way shuttle system for storage.

        2. Outbound operation process

There are many styles of outbound processes, and the specific process is as follows:

        1) Whole pallet outbound

The entire pallet outbound operation of AS/RS three-dimensional warehouse is carried out by the pallet conveyor line to the unloading port on the first floor, and the forklift unloads the goods to the shipping area for collection. When the outbound volume of e-commerce activities surges, the entire shipment will be transported to the e-commerce shipping area on the second floor through conveyor lines, and then split and shipped.

       2) Whole piece outbound

        The four-way shuttle system transfers the entire cargo from the second floor to the high-speed sorting machine on the first floor through a spiral elevator through a box conveyor line, and distributes each order outlet through the sorting system.

       3) Dismantling and picking

        The dismantling operation in this project is mainly divided into three operation areas: box changing area, electronic label picking area, and packaging review area.

        The box changing operation area converts materials that do not meet storage standards into unified turnover boxes and stores them in the four-way shuttle garage. The materials for replenishment are mainly automatically transported from AS/RS and production workshops to the box changing area through the conveyor system.