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© 2012 Material Handling Industry®. Copyright claimed as to audiovisual works of seminar
sessions and sound recordings of seminar sessions. All rights reserved.
Batch Pick Your Way to Higher
Productivity – 5 Methods to Get the
Most Out of Your Picking Operation
Welcome to Session 319
Sponsored by: Presented by:
Tom Coyne, CEO
Two Pictures labeled “Organized
Chaos” on the Internet
Which works better?
Why is this Topic Important?
0% 10% 20% 30% 40% 50% 60%
Other
Setup
Picking
Search
Travel
Time Spent in Manual Order Picking
Source: Tompkins et al, 2003
Managed either
by eliminating
with automation
or reducing with
batch picking
approaches
Travel Time Example
An example of a single order picker picking
(5) individual customer orders. There are
twenty lines to be picked and there are three
items that are on two orders.
Order Pick Batch Pick
Pick faces visited 20 17
Returns to Order
Start 5 1
Distance 1,250 feet 800 feet
% saved 35%
Why Else is this Topic Important?
0%
20%
40%
60%
80%
100%
120%
-
20.00
40.00
60.00
80.00
100.00
120.00
Volume Increasing Over Time ----------------------------------------------------------- >
People Productivity
` • Reduced distances between picks
• Higher pick density per trip
• Congestion
• Lack of Visibility
• Bottlenecks
PEAK !!
Options as Volumes Increase
Man-to-Goods Batch
Picking
Low 40% to 80%
increase in
productivity
Medium – Systems
Low – Training and
Culture
Low to Medium
Goods-to-Man Batch
Picking
Medium to
High
2x to 6x times
increase in
productivity
High – Systems
Medium – Training
Low – Culture
Medium to High
Cost Impact
Ease of
Implementation
Volume Level
to Cost Justify
Labor Management Low 25% to 40%
increase in
productivity
Low – Systems
High – Training and
Culture
Low
Automated Picking High 4x to 6x times
increase in
productivity
High – Systems
Low – Training
Low - Culture
High
Presentation Structure
0
1000
2000
3000
4000
5000
6000
Units Per Hour
Units Per Hour
Goods to Man Batch Picking
Goods to Man basically eliminates Walking
Batch Picking further increases productivity and simplifies conveyor
systems
Many alternatives for the Goods to Man part of the solution
We will first survey man to goods approaches and then
review new approaches for goods to man picking
Man to Goods,
Wave
Picking
Transport
Batching
Mobile Batching;
Carts w/
Lights or Voice
Mobile Batching,
Basic Batch
Carts
Man to Goods,
Single Order
Picking
Batch, Cluster, Wave Picking
What’s the Difference?
• Batch Pick: Visit “pick face” with multiple orders. One visit to pick face for all orders. Eliminates both travel time and processing time.
• Cluster Pick: Visit “pick face” with multiple orders. Visit pick face for each line on each order. Eliminated travel time (biggest issue) but does not as effectively eliminate processing time. Usually implemented in flow rack pick to light solutions.
• Wave Pick: Visit pick face with a much larger grouping of orders (the wave). Pick all items for this wave, but do not yet associate items picked with the final order. Secondarily sort these items to the final order using sorters, put to light/voice systems, or other manual processing approaches.
(4) Example Pareto Chart Shapes
V
o
l
u
m
e
SKU’s’
Low Volume, Early Stage Wholesaler Higher Volume, Later Stage Wholesaler
High Volume, High Sku Operation Very High Volume, High Sku Operation
“Mobile Batching” “Mobile Batching” and
“Transport Batching”
Batch Picking Stations supported
By Goods to Man Picking
Wave Picking to
Unit Sorter
Packaging and Shipping
Order Picking Area
Man to Goods Picking with “Mobile
Batching”
Simple Batch Picking Cart
Seems Simple….but a recent
WMS survey recently indicated
still low usage of batch picking
carts with RF, lights or voice
Batch Cart with RF or
Lights
Man to Goods Picking, “Mobile
Batching” and “Transport
Batching”
Packaging and Shipping
Slow SKU
Order Picking Area
Batch Cart with RF or
Lights
Cluster Picking in Conveyor Zone
Routing System for A Class Movers
Wave Picking and Order Consolidation
Packaging and Shipping
Wave Picking Area
Order Consolidation
Wave Picked and then Sorted using Consolidation Approaches
Wave Picking and Unit Sortation
Packaging and Shipping
Wave Picking Area
Order Sortation
Wave Picked and then Sorted
Goods to Man Survey Robotic Delivery Carousel Systems ASRS Based Systems
Goods to Man Batch Picking Station Survey
Confined Pick Zone,
Automated Order
Delivery
• 200 – 400 LPH
• Good ergonomics
• Moderate Investment
Automated SKU
Delivery,
Wave Picking
• 600 – 800 LPH
• Best ergonomics
• Eliminates
significant conveyor
investments
Automated SKU
Delivery,
Automated Order
Deliver
• 600 – 800 LPH
• Best ergonomics
• Larger investment
Goods to Man Survey
• Carousels historically have been the “standard” approach for break-pack picking of B/C class movers
• Mini-load ASRS historically has been used when inventory levels and/or SKU counts make carousels not practicable
• New developments in technology (shuttles, robotic delivery) make the technology implementation decision more complex
• There is now a “de-linking” of the ASRS solution and the batch picking station.
• The batch picking station can be highly automated, creating a work environment that has almost no walking and is highly ergonomic
Key Benefits to Consider in Goods
to Man Picking and Batch Picking • Reduces operational complexity
• Flexible; SKU’s de-linked from picking activity
• Smaller footprint than goods to man picking
• Makes replenishment and cycle counting more efficient
• Improved order accuracy
• Simplifies slotting
• Simplifies developing store ready cartons
• Much improved job satisfaction
• Easier to own than may be commonly believed
You Can Operate Like THIS OR THIS
You Can Operate Like
OR THIS
© 2012 Material Handling Industry®. Copyright claimed as to audiovisual works of seminar
sessions and sound recordings of seminar sessions. All rights reserved.
For More Information:
Speaker: [email protected]
Home Page: www.systemlogistics.com
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