Managing both rush and
regular orders, as well as
a wide variety of SKUs under
one roof is a challenge for this
busy auto parts DC. Returnable containers help streamline operations.

• Use of returnable containers for picking and shipping streamlines handling of orders and eliminates packaging waste in this pick-to-order operation

• The pallet size (40 by 48 inch footprint) containers come in a variety of heights and collapse when empty for efficient storage/transport

• Use of containers with standard pallet footprint allow handling via pallet jack and counterbalance lift truck

• Items for rush orders can be taken directly from picking areas to shipping so that they can be expedited

• Picking full cases from both bulk storage and floor-level pallet rack locations allows the facility to accommodate SKUs with varying depth of inventory and to maximize the use of space

• Broken case pick module can be expanded on a mezzanine level should volumes increase in the future

• Use of carton flow rack at the dock for staging provides efficient use of space and streamlined handling

Auto repair shops are a bit schizophrenic: They either want their orders to come in on a regular, cost-effective basis, or they want them now. This behavior can sometimes cause the DCs that supply the parts to run two parallel operations. This DC, however, has streamlined its overall operation to the point that all orders travel through a single system. Incoming goods arrive on pallets and are taken to either a single deep pallet rack or bulk storage/picking area, depending on depth of the inventory. The racks are used to replenish a broken case picking area. This dual-sided pick-to-belt operation features flow rack on one side and bin shelving on the other with an inaisle, powered takeaway conveyor. Product is picked to pallet-size returnable containers, which travel via pallet jack from the broken case picking area to the full case picking and pallet picking area. Completed orders are staged in flow lanes at the dock awaiting trailer loading.

Facility Layout

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