peedy order handling is a primary focus at this busy DC, which ships precision machine parts to demanding industrial customers. Approximately one-fifth of the volume requires some type of value-added service (VAS), which adds profit to the facility’s bottom line. Incoming goods arrive in full pallet loads and cases and are staged in floor stacks adjacent to the dock prior to traveling to the reserve storage area, consisting of six-level-high single-deep pallet rack. A pick-to-belt operation consists of carton flow rack and storage shelving. Orders are picked to totes, which are placed on a powered takeaway conveyor and transported to a VAS and packing area located on a mezzanine or directly to a sortation conveyor, where they are diverted to the appropriate shipping lane for LTL (retail) or UPS (catalog) delivery.

• Pallet racks running the length of the facility boost productivity by maximizing runs and limiting the bottleneck at aisle ends

• Wire decking allows for racking of unpalletized products

• Locating the VAS and packing areas on a mezzanine and an overhead sortation conveyor system free up floor space and take advantage of the 30-ft clear ceiling height

• Unique, saw-tooth shaped flow in this facility minimizes travel distances and improves productivity

• SKUs are segregated by activity level in the forward picking area, with the fastest-moving items located in the most accessible areas

• Mixing carton flow rack and shelving in the forward picking area strikes an optimal balance between faces, travel distance, and economics

Facility Layout

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