Light-directed pick cart makes one trip, 60 orders filled

Light-directed pick carts offer operational flexibility, boosting picking rates 400%.

By ·

Traveling through a warehouse can consume time and resources, especially when nearby products require two separate trips. At one PFSweb facility, versatile carts with integrated pick management software significantly improved the speed and accuracy of the order fulfillment process.

The solution uses picking carts that hold multiple order cartons, up to 60 at a time. The carts wirelessly download orders and an onboard display directs the operator to each location in the warehouse. Using a wireless bar code scanner, the operator scans both the storage location of the item in the warehouse and then scans the bar code on the item. The operator then picks items directly into the order carton, which features “put-to-light” displays on each shelf. The displays indicate item quantity and destination, and the operator touches a button on the display to confirm the pick.

The highly portable carts offer operational flexibility as the number of operators can scale up or down depending on the daily order volume.  It accommodates single-line and multi-line orders, enabling high productivity and order accuracy. 

Using this new order fulfillment system, pick rates at the PFSweb facility have increased from 45 order lines per operator per hour to 180 per hour, all while increasing picking accuracy.  In addition, the software enables real-time reporting, such as order status and operator performance statistics.


More Technology coverage.

More from Modern’s 2012 Casebook

About the Author

Josh Bond, Contributing Editor
Josh Bond is Senior Editor for Modern, and was formerly Modern’s lift truck columnist and associate editor. He has a degree in Journalism from Keene State College and has studied business management at Franklin Pierce University.

Subscribe to Modern Materials Handling Magazine!

Subscribe today. It's FREE!
Find out what the world’s most innovative companies are doing to improve productivity in their plants and distribution centers.
Start your FREE subscription today!

Latest Whitepaper
Hydrogen, the Future of Materials Handling
Large, successful organizations are integrating hydrogen fuel cell technology into their lift truck fleets and benefiting from lower operational costs, reduced emissions and improved reliability.
Download Today!
From the October 2016 Issue
Brownells’ new Iowa distribution center has taken touches—and miles—out of the order fulfillment process and increased throughput with near 100% accuracy.
System Report: Brownells new DC is flexible and responsive
Pallet Usage Report: Pallets Remain Critical in the Modern-Day Warehouse
View More From this Issue
Subscribe to Our Email Newsletter
Sign up today to receive our FREE, weekly email newsletter!
Latest Webcast
Pallets: Supporting Product, Processes and the Enterprise
The smallest leak in performance or cost can bring a lean, nimble and speedy supply chain to a halt. During this 30-minute webcast we'll examine how Modern's readers use pallets to keep the wheels turning as they maneuver a road filled with sharp edges and potholes.
Register Today!
Brownells: Designing for Efficiency and Growth
Brownells’ new Iowa distribution center has taken touches—and miles—out of the order...
Industry celebrates National Manufacturing Day
Fourth annual Manufacturing Day is a grassroots effort by U.S. manufacturers to improve the public...

American Eagle Outfitters’ omni-channel journey
The fashion retailer has used warehouse execution software and automation to create a true...
The data-driven lift truck
Now that manufacturers and distributors are using the data from their automated systems to drive...