Logistics News: Continuous Improvement Ideas for Increasing Picking Performance and Storage Space

Here are a couple of low cost ideas that differ slightly from conventional thinking and yet, can significantly increase full case picking and storage space.

While pick-to-belt modules can be very efficient for picking, they are not all that great when it comes to space utilization.

The adjacent sketch shows a typical two level high double-deep pallet flow pick module.  The vertical clearance for the second level mezzanine is shown at 7½ feet above the floor, which is about the minimum requirement for such applications. 

Unfortunately, this arrangement can leave a large void above the top of the pallet loads.  Often, this dead space can be put to good use by installing a shelf of carton flow lanes into the pallet flow rack.  This can be easily accomplished by utilizing standard components readily available from rack suppliers.  Now, this previously dead space becomes a productive on-line picking location for slotting your slow to medium movers, while freeing up off-line static shelving and bin storage space for other uses.

Incorporate Case Flow Shelf into Static Pallet Rack

When walking through the typical warehouse, it is not unusual to find under utilized pallet slot locations.  This may be caused by SKUs that are purchased and received in less than full pallet loads.  Another cause may be that the picking slot replenishment quantity is by the case rather than by the pallet load, or customer orders for particular SKUs are being filled from reserve storage locations. Whatever the reasons, full pallet storage space is being lost.

The adjacent sketch shows how part of a selective pallet storage rack can be equipped with shelves of carton flow lanes to maximize the space. Lane assignment can be random or dedicated. Each SKU can occupy as many lanes as is required.

By utilizing carton flow in the lower bays, you can reduce or eliminate underutilized pallet locations while increasing picking and replenishment productivity.

It’s all about providing more options and having the flexibility to change picking and storage strategies when required.

Optimize Slotting through Continuous Improvement

There are a number of good resources on the Internet on some very good ideas on how to improve picking productivity through the application of proper slotting techniques. One I like is available from Exceed Consulting. Go to that web page, then look under Resource/White Papers for the Slotting document.

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