Serial zone item picking is a popular order picking method where tote boxes or cartons are transported from one picking zone to the next. One of the productivity challenges in this picking method is maintaining a level workload in each zone. If there are too few orders, pickers may become idle. On the other hand, if there are too many orders in a zone congestion occurs and orders move more slowly, potentially starving the downstream zones.
Zone picking productivity can be improved by holding back single line orders and using them to fill lulls in the flow of multi-zone orders. When there are no, or very few, multi-line/zone orders entering a zone, the WMS can release single line/zone orders thus eliminating idle time.
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