OMSAN LOJİSTİK

September 14, 2004 James M. Apple, Jr. The Progress Group, LLC Case Picking and Cross-Docking Mechanization Warehousing Short Course

Case Storage/Picking Systems Agenda Picking Rates Picking Processes Picking Methods Special Case Picking Opportunities

Case Storage/Picking Systems What is a case? – 5 to 50 pounds – Generally shippable, without overpack – Sometimes bags and shrinkwrapped trays – Most are conveyable

Case Storage/Picking Systems Cases picked per hour ! Why such a wide range?

Case Storage/Picking Systems How many do you pick?

Case Storage/Picking Systems Factors Affecting Pick Rate What slows us down? – Walk between picks – Cases/pick – Palletizing – Bending and reaching – Labeling and checking

Case Storage/Picking Systems Factors Affecting Pick Rate What slows us down? – Heavy cases – Oversize cases – Fragile product – Fragile package

Case Storage/Picking Systems Factors Affecting Pick Rate What slows us down? – Congestion other pickers storage and replenishment – Can’t find product – Out of stock – Waiting for work

Case Storage/Picking Systems What makes us fast? Riding, instead of walking

Case Storage/Picking Systems Picking with a Rider Pallet Truck

Using an orderpicking truck to access more SKUs Case Storage/Picking Systems

Case Storage/Picking Systems Factors Affecting Pick Rate What makes us fast? – Easy to locate always in the same place locations logically arranged location ID easy to read – Easy to follow instructions large print pick with one label per case radio frequency –display –voice

Case Storage/Picking Systems Factors Affecting Pick Rate Voice commands

Case Storage/Picking Systems Factors Affecting Pick Rate What makes us fast? – Conveyor take- away

Case Storage/Picking Systems Factors Affecting Pick Rate What makes us fast? – Conveyor take- away but, who does the other half of the job?

Case Storage/Picking Systems Factors Affecting Pick Rate What makes us fast? – Easy to palletize cases the same size or height heaviest cases on the bottom

Case Storage/Picking Systems Factors Affecting Pick Rate What makes us fast? – Good ergonomic access to cases – Monetary or other incentive – Management expectations

Case Storage/Picking Systems System Design Issues 4 ways to pick – Single order – Multiple orders per trip – Parallel zones – Batch pick and sort

Case Storage/Picking Systems Forward Order Selection Area Options Pick from floor level within storage area Forward pick line – Pick to pallet jack – Pick to conveyor Selection at all levels - order selector truck or man aboard crane

Case Storage/Picking Systems System Planning Issues Replenishment – How much to store at pick face – Fixed slotting for “n” days/shifts – Dynamic slotting – Pallet flow lanes

Pick to Pallet From Pallet Flow Lanes Ready-reserve of restock pallets for high mover items Depiction of a pallet jack that carries two pallets for order picking. Replenishment Aisle Pallet flow lanes can be installed in the rack bays closest to the conveyor for the fastest moving products in each product group.

Case Storage/Picking Systems System Planning Issues Zoning the Product – By activity – By throughput cube – by order categories commodity catalog store department/aisle

Case Storage/Picking Systems System Planning Issues How are cases loaded and shipped? – Palletized – Floor loaded – Parcel carrier Order integrity? – Reverse delivery sequence

Case Storage/Picking Systems System Planning Issues Manual batch picking – 2 pallets per trip One order on each pallet – Order picking truck Batch pick slow moving products for several orders and manually sort after picking

2-10 SKUs/ Pallet 1-2 cases to most stores most days Every once in a while a case to a store Total Case Activity 100% Total SKU’s (ranked by activity) 100% Using Pareto’s Law Blocks of activity will help to identify appropriate picking modes. 1 case to some stores some days

Orderpick truck by order Orderpick truck by batch Pick Car Pick to Belt or Induct Full Sorter Automatic Layer Picking Pick to Rider Pallet Jack Walk or ride With Pallet Jack LowMediumHigh Mechanization Alternatives Products Ranked By Activity Total Cases Shipped FAST MOVERS MEDIUM SLOW Item Activity Applying Levels of Mechanization to Classes of Activity

Batch Picking Characteristics Picker stays in zone Shorter walk distance/pick Centralized Palletizing,or Direct Truck loading Automatic check via scanning...but, two people handle each case

Case Picking Economics

Process Steps Picking Mechanization Transportation Accumulation Product Identification Sortation Accumulation in spur Palletizing, or truck loading

Picking Cartons to the Takeaway Belt

Cartons Accumulating Before Sorter

Simple Sorting - select from loop

Simple Sorting - push from conveyor

Right Angle Pusher Sorter

Multi-belt Sorter with Pop-up Wheel Diverts

Sliding Shoe Sorter

Auto-Induct to Tilt-Tray Sorter

Tilt-Tray Sorter Discharging to Spurs

Palletizing at the End of Slide Spurs

Palletizing to Multiple Pallets at a Single Spur

Floor Loading a Truck with Extendable Conveyor

Balancing Pick Zones The picking requirements will not be the same in all zones for each batch. Balanced workload can be improved by: –Slotting products carefully, and reslotting as required –Duplicating the slotting of some very popular products –Letting zone boundaries float from batch to batch

Case Flow To Sorter Wave #1Wave #2 Wave #3 Lost sorter capacityMax sorter capacity Time During the Day Sorter Utilization Carton flow from picking does not arrive at the sorter immediately. The sorter operates most efficiently during the middle of each wave. Flow slows significantly at the end of the wave, as all picking zones do not finish simultaneously.

Recirculation Spurs Typical Shipping Sorter How many spurs should we have? How long should the spurs be? How should we use the re-circulation line?

A Cross Docking Case Study Features –Empty dock at beginning and end of day. –Receipts= total of outbound orders. –Processing determined by: Receipt schedules Product groups –Receipts verified via sorting process

A Cross Docking case study The Environment –Large grocery retailer –Short-life products –9 Depots, each serving 50 stores –24-hour operation –1200 products –100,000 cases per day –Up to 16 family groups – 5 temperature zones –Product and packaging fragility

A Cross Docking case study Current Method –“Pick by Line” –Receiving count for accurate allocation –Manually distribute to roll cages for each store

A Cross Docking case study The Service Challenge –Perfect counts and allocation to stores –Finer family grouping –Reduce package damage –Meet extreme end-of-day peaks

A Cross Docking case study The Cost Challenge –Eliminate receiving check labor intensive delays processing –Improve picking productivity –Improve ergonomics

A Cross Docking case study The Solution –High-speed sortation, 12,000/hour –Ergonomic depalletization induct stations –4 chutes/store for family grouping –Gentle product accumulation in chutes –WMS to manage workload for: family grouping sorter utilization

A Cross Docking case study

Chilled Grocery Products

Unloading Pallets at the Receiving Dock

Scanning an Inbound Pallet

“Grid”, Unload Stations and Sorters

Moving from the “Grid”

Depositing Pallet at Unload

Depalletizing Cases

Q-veyor Accumulation and Merge

5-sided Scanner

Sliding Shoe Sorter

Over and Under Sorters

Loading Roll Cages for Delivery

Labeling for Store Destination

Departing for the Store