This system is designed for simplicity using all conventional storage mediums. For the highly active 20% of the SKUs, the pick-to-light functions are evenly split between two zones and two pickers. The slow-moving 80% of the SKUs are picked from slightly longer zones using pick-to-light and two pickers.

Totes with license plates are used to track the picking effort throughout the system. Hand held bar code readers are used to ensure accuracy. The flowrack and conveyor have a layout that allows high activity kits to pass through the two zones on the front end of the system only. If the order contains slower-moving parts found in the back two flow rack zones, the tote must be single threaded through all four zones before being lifted to the take-away conveyor. Any order tote at any moment that the order is complete is put onto the take-away conveyor where it is immediately distributed to the pack lines by carts.

Click on an image for a larger view This design, while simple, does not truly match the throughput profile of the product. Due to the geometry of the design, it is difficult to man this system efficiently with less than four operators even during off-peak periods when picking is minimal.

Pick Area Cross Section

A more thorough analysis of the order data in this area would most likely show that most totes would not have to go past the two front-end flow rack zones. This system has the potential for very high throughput as long as the SKU golden zoning and SKU activity distribution is done correctly through continual maintenance of SKU location