ORDER PICKING OPTIMIZATION

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World-Class Warehousing and Material Handling

Figure 8.16 Pick-density-based storage at Bertelsmann’s Gutersloh distribution center

Golden Zone

A worn spot in the middle of the picking zone indicates that golden zoning has been applied with most of the picking activity in the middle of the zone.

picking floor is a good indicator that pickers are most often working near the center of the picking zone.

Map Individual Warehouse Locations Within Each Storage Mode into Picking-Activity Zones The first step in this mapping is to plot the pick path through each storage mode. Once the pick path through the pick line has been determined, the definition of the activity zones is fairly straightforward. The two most popu lar pick paths are the serpentine and mainline with side trips (Figure 8.17). In serpentine picking, the order picker will, by definition, travel down each aisle and by each location. Hence, to designate an A-activity zone near one end of the pick line will not reduce travel time. In fact, it may create congestion problems. Instead, the A-activity zone should be defined as the locations that are at or near waist level for broken-case picking and at or near floor level for case picking from pallet racks. In mainline picking with side trips, the objective is to minimize the number and length of the side trips. Hence the A-activity zone should be defined as the locations along the mainline.

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