Material Handling Information - Forward Pick Designs
Forward Pick Designs
Flow Rack with Pick-to-Light and Carousel
Description:
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 a single carousel unit with pick-to-light. Totes with license plates are used to track the picking effort throughout the system. Hand held bar code readers are used to ensure accuracy.
Each order tote is single- threaded through the system. However, once 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.
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This design more closely matches the throughput profile
of the product. The fast-moving 20% group is served
well in the flow rack while the bulk of the slower-moving
material resides in a carousel where it can be picked
with only one operator. While better than Design 1 for
efficiency, it would still require at least two people
during slow picking periods.
Advantages
Capable of matching or exceeding the required throughput.
Operates with only three people at peak rates. Only two people are needed during slow times.
With pick-to-light throughout, accuracy can approach 100%.
Requires less floor space than an all flow rack design, providing more room for expansion.
Disadvantages
Carousels may not be suitable for delicate parts.
Carousels are more difficult to move than flow rack or shelving. You will most likely have to move them at some point in your operation.
During off-peak periods, this system requires a minimum
of two people to maintain efficiency.
More expensive than flow rack or shelving
Carousels require more maintenance than flow rack or shelving.
;)
