Multiple storage/picking
schemes promote
efficient, economic
handling of orders
at this busy mail order distribution center

• Multiple rows of 6-pallet-high, single-deep pallet rack provide a large number of pick faces for 35,000 SKUs

• Sawtooth configuration at the ends of aisles within the rack storage area provide convenient pallet drop-off and pickup locations

• To optimize picking throughput and minimize cost, multi-level pick zone features several types of storage media including bin shelving for slow to medium movers, flow rack for fast movers, pallets for extremely fast movers

• The fastest moving SKUs within each type of pick zone are located in the most accessible areas to boost picking throughput

• Multiple pick zones are provided for the fastest moving SKUs to minimize replenishment activity and cost

• Powered takeaway conveyor in the multi-level pick area is located on the rear side of the pick face so that completed orders can be routed directly to the packaging area, leapfrogging downstream pick zones

• Locating transport conveyor on the rear side of the pick module reduces congestion in the busy picking area

• Rack faces in the multi-tiered pick zone are equipped with light displays, boosting operator productivity and efficiency

Keeping cost in check is a priority at this busy facility, which ships a wide variety of small-to-medium size consumer items to mail order customers. Incoming goods arrive in pallet and case quantities and are transported to random slot locations within a very narrow aisle (VNA) pallet storage area. Pallet rack is configured six slots high with single-deep locations. Product is put away and picked using wire-guided turret trucks. Items are batch picked from a multi-level pick zone that incorporates a variety of storage media, from bin shelving and flow rack to pallet locations on the floor. Pick-to-light technology guides the picker to the proper location and indicates the correct pick quantity. Turret trucks are used to replenish elevated pick zones. Product is picked to totes, which are transported by a powered takeaway conveyor from the picking module to packing stations. Orders are checked for accuracy before being placed into small cases or padded envelopes for shipping.

Facility Layout

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