Increasing Order Picking Efficiencies… One Layer at a Time

Revolutionize Mixed-SKU Pallet Building with Layer Picking

Layer picking applications have steadily gained popularity over the last five years, mainly in grocery & beverage distribution centers, to meet the increasing demand with the ever-expanding SKU volume. Layer picking is an order picking process ideal for high-volume staging or mixing centers. With layer picking, you can quickly build mixed-SKU pallets one or more layers at a time. Layer picking produces an exponential increase in pick rates vs. manual case selection.

Layer picking delivers the results. For example, one forklift operator with a clamping layer pick attachment can fill orders at an average speed of 1250 cases an hour compared to 250 cases an hour manually. That’s a 400% pick rate increase, and by simply using a relatively low-automation layer-pick solution.

Benefits of Layer Picking:

• Just-in-time order fulfillment
• Increased efficiency
• Reduced labor costs
• Increased order-pick accuracy
• Pick up one layer, multiple layers, or full pallet in one “pick”
• Automatic product tracking within the warehouse
• Material-flow data for reviewing processes, order-picking efficiency, and productivity for constant efficiency monitoring

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Layer Picking Options:

Here’s a look at some of the design and application options available for layer-picking systems, from simple forklift attachments to highly automated storage and retrieval systems (ASRS) integration.

• Forklift with Clamp or Suction Attachment – This is a low-automation solution that is highly effective for most mixing areas. Picks one or more layers at a time as needed. The driver then takes the carton layer(s) to an empty pallet positioned at the mixing area’s end (or sometimes in the center). The cartons are deposited, and when the pallet order is complete, a forklift extracts the pallet for distribution or storage.
• Forklift with Clamp & Fork Pallet – This configuration has the forklift operator using the clamp to secure the carton layers but then placing them on a pallet positioned right on the forks vs. driving to the end of the mixing area. The driver then deposits the completed pallet at the end of the lane for pick up.
• Robot Clamping or Suction Tool on Overhead Gantry – High-automation design integrating the warehouse control system (WCS) with the layer pick device. The WCS receives order details from the warehouse management system (WMS) and builds the mixed SKU pallets with minimal labor time and cost.
• Overhead Gantry System Coordinated with ASRS –ASRS provides automatic pallet replenishment to the layer-pick zone. It can also be programmed to extract the completed mixed pallet and position it for distribution or storage.

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Pick Aisle Before Loading

Pick Aisle Post Loading

 

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Take a Look at the Layer Pick Process:

1. High-volume SKUs with a high volume of case picks are stored in a mixing area. The forklift with layer pick attachment moves up and down the lane guided by the driver or an angled floor-mounted guide (photo right).
2. The hydraulic clamp is positioned over the product to select the top layer or multiple layers of cases to begin building the order. The clamp secures the cases and closes in tightly on all four sides, holding them together for safe transport to the waiting pallet.
3. Aisle design depends on space and application. The picked cases are placed on a pallet positioned in the center of the product lanes or at the end of the aisle. At this point, the order is on its way to completion.
4. An order can be partially filled with a layer picker and completed manually if necessary. Adding to the flexibility of a layer pick application.
5. The final pallet may look like this: layers 1 & 2 SKU A, layer 3 SKU B, and layers 4&5 SKU C, etc. It takes only minutes to complete this pallet vs. conventional manual picking.

Restocking can be done in bulk stacking, where forklift operators can also remove the shrink wrap as they restock. Another efficient restocking option is adding pallet flow lanes to the mixing area. Pallet flow lanes automatically replenish the pick face and keep a constant supply of rear pallets ready to move in as the pick face is emptied.

Another way to boost replenishment efficiency and save space is to again use pallet flow for the layer pick lanes while using push-back above to accommodate additional reserve storage. For full-pallet applications, this can be very effective. One caveat to this method is that your application needs to be a full-pallet pick and not a partial-pallet pick. Here’s how that would look:

• The pallet flow lanes feed pallets with high-volume cases to the center pick lane. A pallet separator locks and holds the front pallet approximately 6-12” in front of the rear pallets so that the clamping attachment can easily access all four sides of the layer. Once the front pallet is empty, the next pallet in the lane is released to the front pallet position.
• Pallet flow lanes are quickly replenished from the push-back rack located above the pallet flow lanes.

This is just one example of how customization of existing systems can revolutionize your picking operation. Give us a call to discuss unique layer-picking solutions and automation options. We can work together to find just the right solution for your needs and your budget.