EACH PICKING OPTIMIZATION
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RightChain™ Eaches Each Picking Systems, Principles, and Optimization
• Describe and illustrate alternative broken case picking systems. • Present the benefits, costs, and proper applications for each broken case picking system. • Highlight best and poor practices in broken case picking. • Illustrate a methodology for choosing the appropriate broken case picking system for a particular item.
Contents Course Objectives
RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Bin Shelving
BRONZE ZONE
SILVER ZONE
GOLD ZONE
SILVER ZONE
Bin (or metal) shelving systems are the oldest and still the most popular (in terms of $ sales volume and number of systems in use) equipment alternative for small parts order picking. Bin shelving systems are inexpensive ($100 to $150 per unit), easy to reconfigure and install, and require very little if any maintenance.
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Reserve quantities for primary pick locations.
Contents Bin Shelving Configurations
C
B
Contents Bin Shelving Configurations
A
Reserve quantities for primary pick locations.
C
Contents Bin Shelving Configurations
B
A
B
C Happinet, a Japanese toy retailer, uses pick-to-light bin shelving and ABC slotting for video game picking.
Contents Bin Shelving Configurations Mezzanines
C Items
Contents Bin Shelving Configurations Mezzanines
B Items
A Items
Contents Bin Shelving Configurations Mobile Shelving
RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Contents Modular Storage Drawers
Modular storage drawers/cabinets are called modular because each storage cabinet houses modular storage drawers which are subdivided into modular storage compartments. Drawer heights range from 3 inches to 24 inches, and each drawer may hold up to 400 pounds worth of material. Storage cabinets can be thought of as shelving units which house storage drawers.
Modular Storage Drawers
Storage drawers can be subdivided into a myriad of internal configurations, allowing near 100% utilization of the available storage capacity within a drawer.
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Storage Drawer Configurations
Since storage drawers can be no taller than reaching height, the space above can be used for shelving and/or the reserve quantities for the items in drawers.
Storage drawers may also be stacked several levels tall and accessed with an ASRS machine.
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Storage Drawer Applications
High value items in retail backroom. Urban location.
Small, high value parts for space shuttle repair. NASA
High value items in retail warehouse. Urban area.
Small, high value parts for production line support. GM
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Storage Drawer Applications
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Storage Drawer Configurations
Mezzanine Storage Drawer Systems
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Mobile Storage Drawers
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Carton Flow Rack
Gravity flow rack is typically used for SKUs with a high broken case cube movement, and which are stored in fairly uniform sized and shaped cartons. Cartons are placed in the back of the rack from the replenishment aisle, and advance/roll towards the pick face as cartons are depleted from the front. The back-to-front movement insures first-in-first out (FIFO) turnover of the material.
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Carton Flow Rack Configurations
The space above reaching height is best used for reserve storage quantities of the items in the nearby flow rack locations. Single-deep, double-deep, or push-back racking can be used above flow rack.
Carton flow rack is restocked from the back, insuring first-in-first-out product rotation.
Separating the pick face from the replenishment face reduces congestion, increases productivity, and improves safety.
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Carton Flow Rack Configurations
Light-Directed Picking
Most Active SKUs
Light-Directed Sorting
Shipping Containers
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Carton Flow Rack Configurations
Mezzanines
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Contents Carton Flow Rack Replenishment
Replenishment Trigger Quantity
Labels indicate the number of cartons at which a replenishment should be triggered .
Mechanized Flow Rack Restocking
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Contents ASRS Fl w Rack Replenishment
Carton Flow Rack Configurations
At Avon carton flaps are held back with rubber bands.
Carton Opening
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Order Picking Carts
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Adjustable Batch Picking Cart
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Super Cart
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Golden Zoned Picking Carts
Lifeway's tradition batch picking cart uses golden zoning principles to make sure that most of the sorting activity occurs at or near waste level.
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Wave Picking Cart
This wave picking cart is made of PVC pipe components and is equipped with a fold-down step ladder and document holder. The corrugated totes filled with merchandise are dumped onto conveyors which feed a cross-belt sorting system.
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Contents Intelligent Picking Carts
Intelligent Picking Vehicle
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Intelligent Picking Carts
Cosmetics
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Intelligent Picking Carts
Consumer Products
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Intelligent Picking Carts
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Pick Face Picking Cart
This picking cart in a U.S. Defense Logistics Agency distribution center slides along the front of gravity flow rack bays.
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Monorail Picking Cart
These batch picking carts are used in one of Bertelsmann’s book distribution centers. The carts ride on rails in the ceiling moving between pick zones as orders are assembled into their shipping containers.
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• Light Weight • Durable • Easily Maneuverable • Braking • Storage Density • Sortation Aids • On-Board Scales • On-Board Computing • On-Board Printing • Writing Surface • Trash Receptacle • Housekeeping Devices • On-Board Packaging
Picking Cart Considerations
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Order Picker Truck
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Picker Aboard ASRS
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Pick to Conveyor
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Contents Each Picking Robots
RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Automated Storage & Retrieval Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Vertical Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Rotary Rack Carousels
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Horizontal Carousel Configurations
Light trees direct order picking process.
Pods of 3 bi-directional
carousels eliminate picker idle time.
Sorting matrix and light bar
guides sorting process.
Conveyor from receiving dock allows putaway on the fly.
Golden zone slotting insures most picking activity is at or near waist level.
Mezzanine platform permits picking on two levels.
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Flexible Labor Assignment
Horizontal Carousels
Input Output Conveyor
Rotation Space
Automotive Service Parts
Flue Space
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Horizontal Carousels
Mezzanines
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Rotary Rack Carousel
Each level of the carousel rotates independently in a rotary rack carousel, permitting to all levels at all times. Most rotary rack systems have a robotic inserter/extractor at one or both ends to move totes into and out of the carousel.
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Rotary Rack Carousel Configurations
Laddermatic
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Vertical Carousels
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Vertical Carousel Configurations
This vertical carousel configuration at Kent Dental’s dental supplies distribution center outside of Philadelphia yields excellent storage density, security, and picking productivity for thousands of small, valuable dental supply items.
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Miniload Automated Storage/Retrieval Systems
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Dual Shuttle Miniload ASRS
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Original Bot-Based Miniload ASRS
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Miniload ASRS Configurations | Shuttle-bot Miniload ASRS
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Contemporary Bot-Based Miniload ASRS
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Vertical Lift Module
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Automated Guided Shelving Systems
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Remote Order Picking
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RightChain™ Taxonomy of Broken Case Picking Systems
Broken Case Picking Systems
Automated Dispensing Systems
Picker to Stock Systems
Stock to Picker Systems
Picker to Stock Storage Systems
Picker to Stock Retrieval Systems
Automated Storage & Retrieval Systems
Automated Guided Shelving Systems
Carousels
Picking Carts & Vehicles
Horizontal Carousels
Miniload ASRS
Bin Shelving
Storage Drawers
Order Picker Trucks
Rotary Rack Carousels
Vertical Lift Modules
Carton Flow Rack
Picker Aboard ASRS
Vertical Carousels
Pick to Conveyor
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Automated Item Dispensers
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An Inside Look at Automated Item Dispensing
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Automated Item Dispensing
Carton flow rack lanes are normally stationed behind the automated dispensers, housing the reserve quantities of the nearby items. In this system a takeaway conveyor runs along the top of the dispensing system for empty carton removal.
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Automated Item Dispensing Wall
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Robotic Dispenser Replenishment
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Systems Comparison Table
Syst em Att ribute
Un it of Measure
Bin Sh elving Gravi ty Flow Racks
Storage Drawers
Horizont al Carou sel
Verti cal Carousel
Min iload ASRS
Automat ic Dispensing
Gross Syst em Cost
In it ial Cost/ Purchased Ft3 In it ial Cost/ Available Ft3. Ft3 of inventory housed per Ft2 of Floorspace. Ease of ret ri eval.
$5-$15
$3-$5
$25-$30
$20-$ 35
$40-$70
$30-$40
$300-$600 per d ispenser
Net Syst em Cost
$10-$30
$9-$15
$31-$38
$40-$ 70
$65-$100
$38-$50
Floorspace Requirement s
1-1.2
0.7-0.85
1.8-2.5
0. 8-1 .25
5.0-6.0
4.0-5.0
Human Factors
Average
Average
Good
Average
Excell en t
Excell en t
Good
Main tenance Requirement s Item Security Fl exibil ity
Low
Low
Low
Medium
Medium
High
High
Average High
Average High
Excell en t High
Good Medium
Excell en t Low
Excell en t Low
Average Low
Ease to Reconfigure Order Lines per Person-Hou r
Pi ck Rate
C: 25-125 T: 100-350 M: 25-250 W: 300-500
C: 25-125 T: 100-350 M: 25-250 W: 300-500
C: 25-125 T: 100-350 M: 25-250 W: 300-500
50 -25 0
50-300
25-125
500-1000
Key
T = Tot e Pi cking
C = Cart Pi cking
M = Man Aboard ASRS
W =Wave Pi cking
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RightChain™ Eaches | Pick Mode Optimization
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RightChain™ Eaches | Pick Face Allocation
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RightChain™ Eaches | Slot Location Optimization
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Propose the appropriate broken case picking mode in each quadrant.
BSH = Bin Shelving, GFR = Gravity Flow Rack, SDR = Storage Drawers, HCR = Horizontal Carousels, VCR = Vertical Carousels, MASR = Miniload ASRS, ADP = Automated Dispensing
Cube Movement
Cube Movement
High
Low High
Low High
Popularity
Popularity
High
Low
High
Low
Cube Movement
Cube Movement
Cost of Space ($ per SF per Yr.) Low High Low
Low
Low High Low
Popularity
Popularity
High
High
Wage Rates ($ per Person-Hour)
Low
High
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Propose the appropriate broken case picking mode in each quadrant.
BSH = Bin Shelving, GFR = Gravity Flow Rack, SDR = Storage Drawers, HCR = Horizontal Carousels, VCR = Vertical Carousels, MASR = Miniload ASRS, ADP = Automated Dispensing
Cube Movement
Cube Movement
High
Low High
Low High
Popularity
Popularity
High
Low
High
Low
Cube Movement
Cube Movement
Cost of Space ($ per SF per Yr.) Low Low High Low
Low
Low High Low
Popularity
Popularity
High
High
Wage Rates ($ per Person-Hour)
High
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