Sometimes, the conventional approach to orderpicking is more commonplace than efficient.

In the layout below, workers pick an entire order using a rider pallet jack. That makes for long pick paths. In addition, this layout groups the most popular items front and center, maximizing congestion as multiple order pickers jockey to fill orders. Replenishment of the bottom pallet positions is cumbersome at best.

All that makes for low throughput and an opportunity to improve orderpicking efficiency. On the next two pages, Bob Silverman, president of consultant Gross & Associates (732-636-2666, offers three alternatives to this conventional orderpicking layout.

"As you can see, there are ways to improve what's here for a low or moderate cost," says Silverman. "There's also a chance for an extreme makeover that will deliver the greatest improvements in throughput and
efficiency."

• Pick path is too long
• Poor cube utilization
• Replenishment is cumbersome 
  
   

Low cost, minimum system changes

The first change is to have order pickers pick multiple orders at a time by zone using a double pallet jack. This significantly shortens pick paths.

The most popular items are spread out to minimize congestion. The slow movers are now picked separately with an orderpicker truck directly from reserve storage.

Broken-case picks are made from carton flow rack under selective rack replacing wide span shelving. This shortens the pick path, reduces congestion by separating pickers and replenishers and increases cube use. The addition of pallet flow tracks under selective rack for full-case picking improves replenishment. The new full-case pick tunnel is composed of pallet flow rack for picking, under push-back rack for reserve storage. This system improves replenishment, picking productivity and cube use.

• Multiple orders can be picked at a time
• Replenishment and cube utilization improved
• Storage density improved

Moderate cost, moderate system changes

This layout uses a pick-to-order scheme for broken-case picks Each picker handles only a part of multi-zone orders. Pick-by-SKU (stock keeping unit) is used for full-case picks. As a result, order pickers work in more tightly defined areas, shortening pick paths still further, eliminating congestion and optimizing throughput.

In the three-level, full-case pick module, pallet loads are stored in pallet flow rack. Workers pick directly from the pallet and place the full case on a conveyor running down the center of the pick level. Cases travel by conveyors from the pick modules to a sortation and staging area.

The three-level, broken-case pick module uses carton flow rack to feed cases to pickers. Just as in full-case pick, conveyors take away orders and deliver them to sortation and staging.

Improvements

• Higher picking productivity
• Still better space utilization
• Reduces picker travel distance

For broken-case picking, this is a major leap from the other layouts, bringing in automation in the form of A-frames. This equipment holds individual items in vertical channels angled to meet in the shape of an A. Software drives the A-frame, directing it to dispense individual items onto a conveyor running between the legs of the equipment. Items are dispensed into totes for specific orders. Order accuracy and productivity are both high.

For full-case picking, the three-level module remains. As before, order pickers work in tightly defined zones, eliminating congestion. Conveyors take away picked cases and deliver them to high-speed sortation where they are sent to staging lanes along with totes from the A-frame. Speed of order processing is highest in this layout.

• Radical space and productivity improvements
• Increased throughput
• Shorter order turnaround