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Picking Solutions that Work
by Andrey Kras
November 1, 2017 www.daifuku.com
Picking Solutions that Work by Andrey Kras November 1, 2017 - - PowerPoint PPT Presentation
Picking Solutions that Work by Andrey Kras November 1, 2017 - - PowerPoint PPT Presentation
Picking Solutions that Work by Andrey Kras November 1, 2017 www.daifuku.com What was the life like for a person in old times? Not very diverse After lunch not much As mankind was growing Diversity did get better but only a
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As mankind was growing…
Diversity did get better… but only a little
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But no time of the past compares to our time in terms of Things we consume Things we own
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Today, people ARE what they CONSUME
And they consume more For that, they shop more Hence, they buy more
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The more they do so, the more elaborate their shopping habits become Colors, styles multiply
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Ownership of things defines people, therefore they will increasingly continue to buy more and more Nothing would stop them
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To add to this, people are increasingly becoming compulsive and hence immoderate buyers
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Going to a real shop is still an option
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But many prefer shopping online
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Waiting for deliveries for weeks is no longer tolerated. Delivery times are getting shorter
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Next day delivery is no longer an option. Same day delivery is a demand of the day. And companies strive to meet the demand…
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What do these trends mean to logistics industry?
- A skyrocketing increase of number of orders
- Fewer lines on orders
- Fewer quantity per order
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
Order 890782373
Item Qty
iPhone 7 1 iPhone 7 case 1
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- Burden of stock keeping gets pushed up the supply chain
- Nearly daily stock replenishment in small quantities
- Why? Because no one wants to store at stores any more
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- A finished goods warehouse is no longer for storage only
- A FG warehouse acts as a DC and, in addition to unit
loads, ships often piece-picked items in small quantities.
What does this mean to a manufacturer?
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- An increased demand for storage, since
inbounds are even less balanced with outbounds
- Again, increasingly less outgoing unit loads,
more loose cases, or even pieces
What does this mean to an importer?
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What does this mean to a traditional layout of warehouse ?
- Pallet remains the major unit of storage
- Increasingly more space is given to picking
- perations: pre-picking, batch picking, order
consolidation
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Picking in a traditional warehouse looks something similar to this
Storage Picking
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F 1 2 3 4 5 6 7 8 9 A E B C D
And a picking map similar to this
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How much of the “picking” work time is actually spent on picking?
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F 1 2 3 4 5 6 7 8 9 A E B C D
Order 324273892
Item Location Qty A 1-29-C 2 B 3-21-A 2 C 5-08-C 1 D 6-12-A 3 E 7-43-B 2 F 9-15-B 1
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2 1 3 4
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F 1 2 3 4 5 6 7 8 9 A E B C D
Walking 1 1
0.5
1 2 2
Searching 1+1.5+1+0.5 +1+2+2=9
1.5
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Order 324226545
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 234654635
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 423690345
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 89239702
Item Location Qty DC 3-29-C 2 KF 7-21-A 2 … … … FD 5-12-A 3 JD 8-43-B 2 CC 2-15-B 1
HH 1 2 3 4 5 6 7 8 9 AA KB CC FF GA H A KC C GD G CD B CB DC DD D DB DA DE EE EA EC EB ED FB F FA FE FD FC E JJ GC GG GB GK GJ GF KA K KD KF KE JB J JA JE JD JC KK HA GE B BB
Order 324223564
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 86535574
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 454534578
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 890782373
Item Location Qty E 4-29-C 2 HA 9-21-A 2 … … … FA 5-12-A 3 G 6-43-B 2 GA 6-15-B 1
Order 324223563
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 54238947
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 454534578
Item Location Qty AA 1-29-C 2 BB 3-21-A 2 CC 5-08-C 1 DD 6-12-A 3 EE 7-43-B 2 FF 9-15-B 1
Order 890782373
Item Location Qty AA 1-29-C 2 GB 6-21-A 2 KC 7-38-C 1 … .. .. EE 4-43-B 2 DE 2-15-B 1
AA CC A C CD B CB DC DD D DB DA DE B BB AA CC A C CD B CB DC DD D DB DA DE B BB AA CC A C CD B CB DC DD D DB DA DE B BB FF GA GD G EE EA EC EB ED FB F FA FE FD FC E GC GG GB GK GJ GF GE FF GA GD G EE EA EC EB ED FB F FA FE FD FC E GC GG GB GK GJ GF GE HH KB H KC JJ KA K KD KF KE JB J JA JE JD JC KK HA HH KB H KC JJ KA K KD KF KE JB J JA JE JD JC KK HA
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A B C
Zoning & in-aisle storage optimization
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A B C
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Creating picking zones and optimizing pick faces (A to B to C) do reduce walking of each worker but adds a whole another new operation.
Order Consolidation
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1 2 3 4 5 6 7 8 9
Batch picked Order picked
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With multiple few-line orders, the time required for order consolidation may outstrip by far the time required for batch picking.
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Activity Time Required in Min
Walk 9 Search Scan (Rack, box, piece) 1 Pick 1 Put Complete 1 Walk to Batch Picked Totes 4 Bring them to Order Consolidation Area 4 Consolidate Orders 15 Total Time Req. for Picking 35
Time for “traditional picking”
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26% 3% 3% 3% 11% 11% 43%
Pic icking Tim ime Breakdown
Bring batch to Consolidation Walk to Batches Consolidate Orders Walk & Search Complete Pick & Put Scan
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Automation of picking
- perations eliminates all these
inefficiencies
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Why?
No more walking, nor searching The correct load by itself comes under the picker’s hands
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No more scanning of rack, nor of box* Verification is performed automatically
*Scanning of pieces may be mandated in some cases
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No more batch picking Pick stations allow multiple-
- rder picking at the same time
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No more need in order consolidation Pick stations allow dedicated order picking*
*Some large-scale solutions may require pre-picking and hence consolidation
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Therefore,
Picker does nothing else but
picking
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26% 3% 3% 3% 11% 11% 43%
Con
- nventional Pic
icking Tim ime Breakdown
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Automated Pick icking Tim ime Br Breakdown
Complete Pick Put
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Now, how this works
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Storage Buffer Palletizing Picking
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Stock Supply Return
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Goods In Goods In ASRS: approx. 7,000 PL DPS: approx. 2,000 SKUs Sorter: 30 chutes; 390 PL Goods Out Goods Out
130 PL /D 2,500 cs /D 300 PL /D
9,000 lines/D 170,000 pieces/D
14-hour shift
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Case Picking
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Digital Pick System
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DPS Replenishment
Input of Shipping Containers
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1 2 3 4 5 6 7 8
Multiple Order Pick Stations
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Pre-Shipping Container Source Container
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