All distribution centers contain different assortment methods for full pallets, boxes, or items. This publishing focuses on item assortment. Item refers to the smallest possible division of a product for order fulfillment. There are various technologies to facilitate item assortment, each of them adapting to the desired output rate and the type of product to be handled.The following is a list of 6 effective technologies that will assist you in handling this type of operations:
1.- Radiofrequency (RF)
RF is the most basic semi-automated system for item assortment. It is guided by a mobile PC, which points to which location should the system move, how many parts should be taken and, finally, requests a confirmation for the operation. All of this is controlled by WCS or WMS software technologies.
RF works according to the assortment configuration setup by the operator. Such may be by “order by order” assortment or by “consolidated / pick cars”. Pick car refers to an order consolidation which doubles, or even triples, productivity, offering from 150 to 300 lines per hour.
2.- Voice Picking
Voice picking is used in order assortment whenever lacking significant space between items, or when there is medium to low item rotation.
Voice Picking usually indicates where should the operator go, and provides a confirmation for the operation. The key for choosing this technology, which provides flexibility for the project, is having a large storage space, sufficient SKUs, and medium to low rotation. Besides items, voice picking is frequently employed for box assortment.
3.- Horizontal / Vertical Carousels
Carousels assist in the operation of multiple medium-to-low-rotation SKUs. The productivity range handled is 200 to 500 lines per hour (depending on the type of arrangement inside the workstation).
This product-to-man type technology saves time and efforts for the operator, avoiding his need to walk and search for SKUs by moving the product to the location where employees require it. Carousels are ideal for item assortment in all types of industries thanks to their high cost/productivity ratio. They are usually complemented with Laser Pick and Pick to Light systems so that operations are controlled in real time.
4.- Pick to Light
Pick to Light allows the operator to access the product through the use of indicator lights. These lights indicate the places where the product should be retrieved and the exact number of items.
Pick to Light technology provides a higher product rate while reducing movement and saving time; all this through the use of more direct instructions.
This solution works in assortment zones and when some parts can be turned into hybrid; that is, zones that can be interlinked or combined. When combined, Pick to Light allows the displays to be lighted up and, with assistance from the system software, use different colors for each operator, thus indicating the actions to perform. This combination further increases productivity.
Not using fixed zones allows assortment distribution as per each specific order, thus balancing workloads among all operators.
5.- A/FRAME
A/Frame solutions are usually employed in operations with very large output rates, from 2,000 to 2,500 lines per hour. This technology provides the necessary rate for regular products, as long as the packaging of such products is not easily deformed (such as with medicine packs). It is efficient for product stacking and transfer of SKUs directly into the box.
The key for choosing this assortment solution is having plenty of SKUs regularly, as is the case with cosmetics, electronics, and pharmaceutical industries, among others.
It is a system that requires a significant investment. However, the same may be adapted into accesible modules for a few implementations, connected to your ERP, WMS, WCS, or WES system. This helps achieve great productivity increases.
6.- Shuttle
Shuttle technologies are used in medium-to-high rotation products. Their main advantage is saving space, since they can reach up to 30 meters in height. Shuttles are high stowage tools; no other system has this flexibility.
Shuttle is complemented using the Laser Pick technology, while recording product inventory management in real time. It also has a random warehouse, since the software itself locates the best position to optimize machinery storage. It allows having multiple access, since it handles two trays: one delivers the products, while the other fulfills the following order.
You may have 2 or 3 different technologies implemented together to increase productivity in SKU assortment. To do this, a previous analysis of several factors is necessary to pick the best choices. Avoid crisis in your assortment processes caused by inadequate tools within your distribution center.
We can assist you with developing an analysis of your operations to determine the best alternatives that translate into productivity and full control of all your processes, so that your operation becomes a true backup for your customer service.
