From SCDigest's On-Target E-Magazine
- July 31, 2013 -
Supply Chain News: A Carton Sortation Dictionary 2013
A Refresh of Our Popular Glossary First Published in 2008 to Help Logistics Managers Considering Sortation Systems
SCDigest Editorial Staff
Half the battle for companies and individuals new to carton sortation systems in distribution is getting the comfortable with all the terminology used by vendors and consultants.
SCDigest first published a "Sortation Dictionary" back in 2008. Now, we are republishing it for 2013, for the benefit of new readers and even long-time subscribers who may now have interest in carton sortation systems. We have also added several new terms for 2013.
We are confident you will find it useful.
SCDigest Says: |
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| Waveless picking is a relatively recent concept that comes from some automation providers that believe traditional wave picking often does not optimize automation/sortation system performance. |
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What Do You Say?
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Batch Picking: The fundamental concept that drives the value of most carton sortation systems, and which can be contrasted versus traditional "discrete order picking" approaches in with each order is picked by itself. Discrete order picking means each location that has a SKU in an order is visited for each order. In batch picking, orders are grouped together by the WMS, typically in a wave (see below), such that each location is visited just one time for multiple orders. The sortation system then later takes care of dividing the cartons back into individual orders. The labor savings from much lower travel time from order batching provides most of the cost-justification for sortation systems.
Pick Modules: Dedicated areas, specially constructed areas for full case or split case picking served by a takeaway system such as a belt conveyor. Pick modules are often multi-level rack structures using pallet or case flow storage (see below). Generally in a pick module, there is storage on either side of the takeway conveyor, and pickers on both sides can place cartons on it for conveyance to the sorter.
Induction: The process of identifying the product to be sorted, getting the product moving at sorter speed, and ensuring there is the appropriate gap between boxes for the specific sorter application. The sorter needs to be fed by the induction system at the rate of the intended sorter performance (e.g., 125 per minute). Usually involves a bar code scanner and a series of belts that move at different speeds to create carton gaps - a process made more challenging by today's very high speed sorters that can operate with very small gaps between boxes.
Merge: As the name implies, a merge point is basically an area where product from one part of the total conveyor system is inserted into the main conveyor line leading to the sorter itself. Increasingly sophisticated controls and technology is being used to accomplish merge processes at ever-higher speeds today. A typical example would be a merge coming out of a given pick module into the main conveyor line. Merges come in several types, generally named according to the way the physical design looks (sawtooth merge, herringbone merge, etc.), and each is best suited to different applications.
Print and Apply: Sub-systems that apply a label in-line on the conveyor system prior to the merge point. Sortation systems generally need have each carton uniquely identified, usually by a bar code and perhaps in the future perhaps RFID. If cartons are not pre-labeled with a unique bar code identifier, then companies have two choices: pickers can apply labels to cases during the picking process, which degrades productivity, or they can deploy an in-line print and apply system. Generally, a scanner reads a generic case bar code, and a sub-system (perhaps part of the Warehouse Control System) looks up order and other information for that SKU. A label is then printed and applied at high speed (approximately 30-40 per minute for variable 4 x 6 labels) with a unique serial number for that case. That label often serves as the shipping label, such as the GS1-128 label used by consumer goods companies shipping to retail. In other sectors, it may be a smaller label that contains just bit of text and a serialized bar code.
Pallet Flow Rack: A storage type often use in full case picking modules that presents full pallets of product from which cases are picked and placed on take-away belt conveyors. Pallet flow rack can be single or double deep (or sometimes more); fresh pallets are replenished from the back; empty pallets are removed from the front.
Case Flow Rack: A storage type often used in split case pick modules that presents a single open case to order pickers. When the case is emptied, it is removed, and gravity forces the next case to the picking position. Replenishment of case flow racking is from the back.
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Slug: A group of boxes that moves as a set on the conveyor system. The most common application may be merging a slug from a pick module onto the main conveyor. The control system will determine the size of the slug, which may be all the boxes awaiting a merge, or just a portion of them, depending on conveyor conditions at the time.
