Commercial
electronics DC

A multi-zone picking strategy and efficient conveyor transport/sortation system keep operations at this high-activity facility humming

• Locating receiving and shipping on opposite sides of the building streamlines flow of goods and minimizes travel distances

• Multi-level pick modules on mezzanines provide for efficient use of space and maximize picking capacity

• Mixed use of flow rack and bin shelving in picking modules allows for increased depth of inventory and fewer replenishments of the fastest moving items

• The combination of double and single deep rack allows the facility to efficiently accommodate SKUs with greater depth of inventory, while maintaining an equal number of available pick faces

• Unique conveyor design marries broken case and full case orders that are fulfilled on opposite sides of the facility

• Locating the conveyor transport and sortation system overhead minimizes congestion on the ground at this busy facility

• Should business increase, both conveyor sortation and shipping/staging lanes can be expanded

The challenge this DC faces is to efficiently manage orders that consist of a combination of broken case, full case, and full pallet quantities. Incoming orders arrive at receiving and are taken to a pallet storage area, consisting of fivelevel- high single and double deep pallet rack. The facility maintains separate areas for full and broken case picking operations Both are multi-level modules with upper levels located on mezzanines. Broken case items travel to packing stations, where they are placed into shipping cartons. Full cartons from both the broken case and full case picking areas then travel by overhead conveyor transport system to a common sortation system, where they are sorted to staging lanes by retail store location. Full pallet loads are staged on the floor adjacent to the appropriate shipping lane.

Facility Layout

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