ORDER PICKING OPTIMIZATION

Chapter eight RightPick RightShip: Order Picking and Shipping

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Figure 8.10 Traditional U-shaped warehouse configuration

Broken Case Picking

Case Picking

Pallet Storage and Retrieval

Order Assembly

Cross Docking

Inbound Staging

Outbound Staging

storage, broken-case picking, packing, accumulation, shipping staging, and shipping docks. Why do we need so many different storage and picking areas? Why do we need separate forward areas for case and broken-case picking?The reason is that broken- and full-case picking productivity from a large reserve pallet storage area is low. The forward areas are small and compact, are uniquely configured for the picking task, and may have specialized equipment. As a result, the picking productivity in these areas is 10 to 20 times less than the productivity in a large reserve storage area, where the entire inventory for a single itemwould be housed. The picking productivity gain is almost always so great (compared with picking from reserve storage locations) that the cost penalties paid for replenishing the forward areas and the space penalty paid for establishing these stand-alone areas are rarely considered. Now suppose that we could achieve forward picking rates from a reserve storage area? In so doing, we can have our cake and eat it too—excellent picking productivity, no forward-area replenishment, and no extra space set aside for forward areas. Is this possible? It is in Ford’s service parts distribution centers.

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