OMSAN LOJİSTİK

- 2 - Day 2Day 1 Session 2 – Afternoon Process and Technology Alternatives Pallet Storage Case Picking - Manual - Mechanized Session 3 – Morning Process and Technology Alternatives Small Item Picking - Order Picking Methods - Forward Pick, Slotting, and Replenishment Mechanized Picking Systems - Zone Picking - Batch Picking Session 4 – Afternoon Putting it all Together Developing the integrated design - Sizing the Functions - Defining Overall Facility Flow - Orienting Shipping and Receiving - Planning Aisle Patterns Integrating Human Activity Session 1 – Morning Defining the Problem Context - Supply Chain, Distribution Network - Single Warehouse Operations Logistics Activity Profiling Case Picking—Manual

- 3 - Warehousing—Do You Know? Case Handling How fast can a person pick cases? –Pallet-to-pallet? At the floor? In the air? –Pallet to conveyor? How fast can a person load cases into a truck... –With a lift truck? –From a pallet? –From an extended conveyor?

- 4 - Case Picking—Manual Session Topics Picking Rates –Pick rate ranges –Factors affecting picking rates—what makes us fast or slow? Picking Equipment Examples –Powered rider vehicles –Person-up order picking truck System Planning Issues –Storage options –Storing less-than-pallet quantities –Picking methods –Forward order selection options –Replenishment –Zoning –Loading and shipping –Batch picking Selecting optimal picking modes Case picking economics

- 5 - Picking Rates What is a Case? 5 to 50 pounds Generally shippable, without overpack Sometimes bags and shrink-wrapped trays Most conveyable

- 6 - Picking Rates Cases Picked Per Hour Why Such a Wide Range? !

- 7 - Picking Rates How Many Do You Pick?

- 8 - Factors Affecting Pick Rate What Slows Us Down? Walk between picks Cases/pick Palletizing Bending and reaching Labeling and checking Heavy cases Oversize cases Fragile product Fragile package  Congestion  other pickers  storage and replenishment  Can’t find product  Out of stock  Waiting for work

- 9 - Factors Affecting Pick Rate What Makes us Fast? Easy to locate –always in the same place Easy to follow instructions –large print –radio frequency display Voice Conveyor take-away –but, who does the other half of the job? Easy to palletize –cases the same size or height Good ergonomic access to cases Monetary or other incentive Management expectations

Picking Equipment Rider Pallet Trucks

Picking Equipment Picking with a Rider Pallet Truck

Picking Equipment Person-Up Order-Picking Truck

System Planning Issues Storage Options Block stacked pallets Selective pallet rack Double-deep or push-back rack Unit load AS/RS Decked pallet rack or shelving

System Planning Issues Storing Less-Than-Pallet Quantities Short pallets Shared pallets Shelving Carton flow rack –when entire receipt fits into lane

System Planning Issues Picking Methods—Four Ways to Pick Single order Multiple orders/trip Parallel zones Batch pick and sort

System Planning Issues Forward Order Selection Area Options Pick from floor level within storage area Forward pick line –Pick to pallet jack –Pick to conveyor Selection at all levels - order selector truck or man aboard crane

System Planning Issues Replenishment How much to store at pick face Fixed slotting for “n” days/shifts Dynamic slotting Pallet flow lanes

System Planning Issues Zoning the Product By activity By throughput cube By order categories –commodity –catalog –store department/aisle

System Planning Issues How are Cases Loaded and Shipped? Palletized Floor loaded Parcel carrier –Order integrity? Reverse delivery sequence

System Planning Issues Manual Batch Picking 2 pallets per trip –One order on each pallet Order picking truck –Batch pick slow moving products for several orders and manually sort after picking

Using Pareto’s Law Blocks of Activity Help Identify Appropriate Picking Modes 2-10 SKUs/ Pallet 1-2 cases to most stores most days Every once in a while a case to a store Total Case Activity 100% Total SKU’s (ranked by activity) 100% 1 case to some stores some days

Orderpick truck by order Orderpick truck by batch Pick Car Pick to Belt or Induct Full Sorter Automatic Layer Picking Pick to Rider Pallet Jack Walk or ride With Pallet Jack LowMediumHigh Mechanization Alternatives Products Ranked By Activity Total Cases Shipped FAST MOVERS MEDIUM SLOW Item Activity Applying Levels of Mechanization to Activity Classes

Batch Picking Characteristics Picker stays in zone Shorter walk distance/pick Centralized Palletizing,or Direct Truck loading Automatic check via scanning...but, two people handle each case

Case Picking Economics Manual picking Batch pick to conveyor Hourly case picking requirement Picking rate Loading rate , Number of operators required for varying pick rates and case activity It requires very high throughput rates to justify the capital expenditure for an automated system