Pick rates for put systems are typically higher than conventional discrete order picking systems where there is a pick face for every SKU. Based on industry statics operations that migrated to put order fulfillment can increase picking rates from 1.5 to 3 times depending on the system configuration.
However, while a put system may be great for slow movers, it may not be ideal for fast movers. Still, based on the Pareto Curve, where 20% of the SKUs equate to 80% of the volume, improving picker productivity for the remaining 80% of the SKUs would most likely prove to be a good investment strategy.
In some cases distributors are deploying horizontal carousels to handle slow movers. For example - Coty Inc., the world’s largest fragrance company, found that while its 900 slowest moving SKUs amounted to only about 2 percent of total volume, they led to substantial bottlenecks in order processing. Coty implemented two 65 foot long, five-shelf, light-directed horizontal carousels, which led to much more effective picking operations and storage density for those slow movers.
It is noteworthy that carousels are used extensively in service parts distribution – an environment often characterized by huge numbers of mostly slow moving SKUs. Logistics Consultants, Industry Experts, and/or System Integrators can do the ROI analysis.
Light-Directed Put Sortation System
Put-to-light and/or Pack-to-Light are variations of put order fulfillment systems. Put-to-light commonly refers to the distribution of a product across multiple locations, where each location contains a pallet load, container or tote that is associated to an order. Pack-to-light is more specific because it implies that the location holds the shipping container that is delivered to the store/customer.
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