Related to crossdocking is the concept of sequencing, or picking products in a certain order to expedite handling and putaway once they reach their locations. The auto industry and other manufacturers have perfected sequencing of parts for their assembly operations. They order specific items from their suppliers and expect that they will be delivered just-in-time and in the same sequence as they will be needed on the assembly line.

Likewise, many retailers look to sequence products as they are picked to reduce work once the items hit the stores.

Pep Boys, the auto parts retailer, sequences parts as it picks them to make it easier to restock retail shelves. Products are stored in pick modules within its DCs in family groups containing like items. This makes putaway in the modules easier and improves slotting within the building. It further reduces product damage, as heavy items are not accidentally assigned to slots above more fragile items.

Pep Boys' retail stores are laid out to reflect the same family groups as in the DCs, with similar products shelved together. To fill orders, items are picked into totes from the family groups as close to aisle sequence as is possible.

"All of the products within a tote are designed to be putaway within three to four aisles of the store," says David Raetsch, engineering project manager. "Our goal is to reduce putaway time."

"On average, we save 35 man hours per delivery by sequencing products," adds David Schneider, director of logistics support. "If a store gets two deliveries a week, that is 70 hours that week that can instead be used at the store helping customers."