Material Handling Information - Forward Pick Designs
Forward Pick Designs
Flow Rack with Pick-to-Light and Mini Load
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 aisle of a mini load automated buffer. 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 is similar to Design 3 except that the slow-moving
bulk material is stored and retrieved in a mini load
automated buffer. The fast-moving 20% group is served
well in the flow rack, while the bulk of the slower-moving
material is buffered in the mini load where it can be
picked by only one operator. This has two main advantages
over carousel: 1. Uses less floor space; 2. Inventory
is computer controlled and orders are brought to the
picker one at a time, eliminating most picking errors.
Advantages
Capable of 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 previous designs, providing more room for expansion.
Offers better ergonomics for slow-moving parts.
Unlike carousels, the mini load does not move the entire inventory with each pick.
Disadvantages
Automated equipment is more difficult to move than flow rack or shelving.
During off-peak periods, this system requires a minimum
of two people to maintain efficiency.
More expensive than flow rack or shelving
Automated equipment requires more maintenance than flow rack or shelving.
;)
