Material Handling Information - Forward Pick Designs
Forward Pick Designs
Flow Rack with Pick-to-Light
and Mini Load for Automated Replenishment and Picking
Description:
This hybrid system is similar to Design 4 except that it has the major advantage of absolute control over all inventory, including replenishment. It 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 the end of the aisle of a single mini load automated buffer 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.
This system has the potential for the highest throughput of any system as long as the SKU golden zoning and SKU activity distribution is done correctly, which would require continual SKU location maintenance.
In addition, this is the only system with the flexibility
to adapt quickly to changes in production. The high- speed
pick locations in the flow rack can be reconfigured on the
fly very easily.
Click on an image for a larger view
If flexibility is the goal (cyclic pick rates), then
this design is hard to beat. All of the material is
stored in the mini load. Automatic computer-controlled
replenishment to the flow rack ensures that the two
high-speed pick zones always have material during peak
picking periods. During slow periods, the picker at
the end-of-aisle can pick all orders. This is the only
system that can truly be managed efficiently by one
operator. This system also offers the most storage capacity
per floor space used.
Advantages
This system offers the most flexibility of any system for picking, replenishment, and re-zoning, making the most efficient use of labor.
This is the only system that can operate efficiently with
just one person during off-peak periods; from a single location
at the end of the mini load aisle, one picker has access
to all products.
Capable of exceeding the required throughput
Operates with only three people at peak rates. Only one person is needed during slow times.
With pick-to-light throughout the flow rack, accuracy
can approach 100%; automated replenishment will also dramatically
increase accuracy.
Offers very high density storage in a compact footprint, saving floor space.
Offers better ergonomics for slow-moving parts as well as for replenishment.
Offers an easy way to pre-build and store high-volume, high-use kits, requiring fewer employees and supporting faster response times.
Disadvantages
Automated equipment is more difficult to move than flow rack or shelving.
More expensive than flow rack or shelving
Automated equipment requires more maintenance than flow rack or shelving.
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