This hybrid system is designed to exactly match the activity profile of the parts based on the given data ( i.e., the 80/20 rule). For the highly active 20% of the SKUs, the pick-to-light functions are evenly split between two short zones and two pickers.

The slow-moving 80% of the SKUs are picked from conventional shelving with a pick-to-light system. Totes with license plates are used to track the picking effort throughout the system, with hand-held bar code readers used to Ensure accuracy.

Each order tote is single threaded through the system. However, at any moment that the order is complete, it is pushed onto the takeaway conveyor where it is immediately distributed to the pack lines by carts.

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 first or second flow rack zone. This system has the potential for very high throughput as long as the SKU golden zoning and SKU activity distribution is done correctly, which would require continual SKU location maintenance.