Order Fulfillment Productivity Enhancements through the use of Zone Routing Conveyor Control

04/20/2006

Conveyor based order routing is a great concept to reduce labor and improve picking for multi-line orders. This concept can support both pick to carton or tote provide an efficient means to route the work to the operator by deploying two or three level Pick Module. Multiple modules can be linked through the conveyor route to support thousands of SKU’s.

In basic order fulfillment systems, orders are either picked to carts or totes and the order moves manually between zones (Pick-Pass). Picking personnel (Pickers) typically examine paper based pick sheets to determine picking activity. Each order must be handled numerous times, creating wasted labor, pick errors, longer order processing time, and bottlenecks throughout the pick process.

Conveying Controls Corporation, a Numina Group Company, is a leading supplier of Zone Routing Conveyor Systems for Distribution Centers. Dozens of systems have been implemented for companies such as Timex and CDW, Computer Discount Warehouse Inc. These firms have realized tremendous labor and order fulfillment time savings through the implementation of intelligent pick routing conveyor systems.

In Zone Routing, order picks start at either the first pick zone or a designate start zone and visit only zones at which a pick is required. Pick modules are divided into reasonably sized zones based on SKU’s movement history. Pickers work a set pick zone (typically 60-100’) to reduce walk time and improve picker efficiency.

A bar code or R.F. tag based control system is used to track product movement and control the route decisions. The Control System automatically routes orders to only the zones requiring picks, eliminating redundant handling labor and reducing order completion time through the warehouse.

The Numina Groups, Real-time Distribution System (RDS) Software, the USA’s leading Linux Warehouse Control and Execution System (WCS) includes a Pick Route Module that manages the overall picking operation. RDS determines the most efficient route and supervises the conveyor control system to ensure cartons are routed only into those zones where picks are needed. Paper based, RF terminals, Light Directed Picking or Voice Directed Picking are supported to directs and confirms operator picking throughout the process.

Additional RDS software modules support in-motion weight and vision inspection (see VPAK System for more details) to validate the order picking process.

RDS can simultaneously communicate with WMS and ERP systems and control - manage100’s of conveyor control divert/route decisions, Order Fulfillment Sorters, high speed Pack and Ship Sorters, and other material handling technology found in high volume distribution centers.

For more information contact:

Dan Hanrahan
The Numina Group
10331 WERCH DRIVE,
WOODRIDGE, IL 60517
Phone: (630) 343-2600
Email: dhanrahan@numinagroup.com
Web site: www.numinagroup.com
 
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