Demand for reduced fulfillment time, improved labor productivity and better use of space is driving high-performance order fulfillment methods in many of today's DCs. A medical supplies wholesaler recently deployed a new order fulfillment system using a high-density, mini-load automated storage and retrieval system (AS/RS) with a new multiple shuttle technology (Dematic, 877-725-7500, www.dematic.us).

The mini-load features load-handling carriers on each level in a high-density rack structure where loads are stored and retrieved automatically. By having multiple shuttles, or a carrier on each level, the mini-load allows for ultra high throughput rates. The system is modular and scalable, so tote staging locations expand easily, allowing flexibility if SKUs are added or more storage is needed.

As a result of the installation, the wholesaler is realizing significant cost savings and improvement. Dedicated pick faces and picker travel time have been eliminated, and both single- and multiple-line orders require less time and space to process.

The system design also provides improved ergonomics, increased product security, sequenced product by grouping (heavy, light and liquid), and decreased picking errors (from 1% to less than .01%) in a very compact system footprint.

One operator station is dedicated to feeding the product storage system with the required SKUs. Two operator stations are used for order picking. Four operator stations are used for packing. When staffed, the workstations operate independently so one worker is not affected by workers at other stations. Stations can be taken in and out of service depending on the daily volume requirements and not all stations need to be staffed to complete order fulfillment.

The dedicated operator workstations feature ergonomic designs that improve comfort and productivity. And because workers don't move around the warehouse and SKUs come to them one at a time, the chance to pick the wrong item is eliminated and accuracy is improved.