Order Processing Systems –There’s Much to (Case)-Pick From

Apex Gives the Breakdown on Case Picking Options

Low-cost, high-efficiency case picking is a tall order, and with so many options to explore, it can be daunting to create just the right mix of material handling solutions to tackle that challenge. The Apex team has decades of experience in designing customized case-picking applications, so we’re happy to share some of what we’ve learned over the years and help those of you looking for better, new solutions to narrow in on the best tools for the job.

Selective Pallet Rack

Traditional case picking often relied on order selection from lower-level and floor-level pallets in selective rack. While this basic method is still a go-to in certain order fulfillment situations, the process can be inefficient, resulting in increased forklift and order picker travel and picking time.

Hand-Stack Bays

Selective pallet rack can be equipped with wire deck or solid surface decking above floor-level pallet storage for hand-stacked carton storage and case picking order selection.

Split Pick Beams

First level, aisle-facing pallet rack beams can be modified to create an opening for order pickers to enter the rack to access rear cases on the pallet. The front beam is split and either curved/or angled back to bolt to the back beam, creating the opening. Single and double-deep options are available.

Industrial Shelving

Cost-effective and flexible, simple carton shelving is ideal for inventory with an abundance of SKUs and generally low pick quantities. It is beneficial for each picking of slow movers, parts supply, and assembly, as well as e-commerce. The challenge of shelving storage is inventory replenishment so that pickers are not slowed down or waiting for restocking.

Carton Flow

Carton flow is a first-in/first-out (FIFO) gravity-fed solution for storage of multiple-deep cartons and totes. Made of slightly included wheeled or roller tracks and shelves, cartons are loaded from one side of the lane (the load aisle) and flow to the opposite pick aisle for order fulfillment. Carton flow is available as stand-alone units or integrated into floor-level pallet rack or pick modules.  Carton flow installed in the lower levels of the selective rack increases the number of pick locations, improves ergonomics vs picking from floor-level pallets, provides automatic pick face replenishment, and reduces picking/replenishment traffic. For more info on carton flow applications – see our recent blog.

Pick Towers

Pick towers are popular high-density storage and picking solutions that maximize storage capacity and increase pick rates for full-case and split-case picking. A pick tower is basically a single-level storage structure equipped with carton flow and/or pallet flow (for case pick from pallets) to facilitate faster picking vs. from static rack or shelving. The dynamic nature of the flow racking provides automatic pick face replenishment, so pickers aren’t left waiting for restocking. The restocking happens from the outside aisles, separating forklift and picker activity. Your total SKU count, individual SKU volumes, and order fulfillment goals will determine the design of your pick tower. The Apex team can help customize the most efficient use of your space to meet your needs.

Multi-Level Pick Module (Left) – Pick Tunnel (right)

High-density pick towers are a cost-effective solution vs. warehouse expansion. Most often, this is a beneficial set-up for kitting and batch-picking operations where an order picker picks related groups of SKUs for a batch of orders in a single pass through a pick area. Hence, the configuration of your pick tower is paramount to the success of the system.

Pick Modules

Pick modules take your pick tunnel up a level…. These designs create a pick aisle for case, or single item picking, with reserve storage above. Generally, cases are picked from the rack to a conveyor that runs the length of the aisle. You can also pick to pallet jack or cart if you are pallet building vs. fulfilling smaller individual orders. Pick modules are ideal for fast- to medium-turn SKUs with a high order volume. Pick modules support zone-picking applications to minimize worker travel and search times while increasing pick rates. Consider adding carton pick automation to improve pick speed and accuracy.

The lower-level carton flow is resupplied from full pallets stored on the top rack levels. The reserve pallets are loaded from the outside aisle by the forklift, which isolates the workers inside the pick module from the vehicles. Pallet flow rack is often used to store the pallets keeping SKUs organized and at the ready.

Layer Picking

What about picking a full layer, or more, of cases from a pallet in a single pick? That is layer picking. High-volume staging or mixing centers are designed so that full layers of cases can be picked in one single pick from a pallet using a clamp or suction attachment device. Layer picking produces an exponential increase in pick rates vs. manual case selection. Grocery & beverage industries are prime targets for layer picking as they strive to meet the increasing demand and an ever-expanding volume of SKUs.

Design and application options for layer-picking systems range from simple forklift attachments to fully-automated ASRS integration. For more information on layer picking, see our recent blog.

Picking Automation

While we have focused on different structures and configurations that accommodate picking scenarios, it is important to note that there are several types of electronic systems available to increase the speed and accuracy of order fulfillment. Pick-to-light, voice-direct picking, and bar-code scanning systems can all be integrated into any of these different case-picking system configurations.

When choosing the order-picking solution, note that the systems and methods must be predicated on current and historical inventory cycle times as well as future expectations. Frequent inventory analysis will ensure that your picking and order processing are optimized… with the understanding that even reconfiguring your inventory storage for seasonal or market changes is often less expensive than running inefficiently.

Apex can assist you with a material flow analysis that will help identify the best order-picking methods to minimize per-unit costs and maximize efficiency. Give us a call today to get started.