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Scale your pick module to fit your exact space and process
While there is no such thing as a standard pick module, they all share common traits. Pick modules integrate various storage solutions inside multi-level work platforms that move product efficiently through a distribution facility.
These order picking systems are multi-level, and combine elements of mezzanines and work platforms with conveyors (often for takeaway), carton flow racks, pallet flow racks, static racks, carousels, and other equipment that delivers loads for pickers on each level. Details: what comprises a pick module.
Pick modules produce faster picking in less space than floor level or simple rack or shelving storage. This results in significant cost savings for broken pallet, full-case or open-carton picking functions. This reduces wasted "walk time" for pickers, who are situated in areas where they spend more time picking orders and less time finding SKU's. Orders are typically conveyed away from the pickers to packing and shipping. This reduces picking times and increases accuracy. You can integrate pick-to-light or voice directed picking into your system to provide fast, accurate order fulfillment.
How pick modules improve picking operations, storage density, inventory control and labor utilization
Enforce inventory rotation with first-in, first-out picking
Replenish inventory from the load side and your pickers are always presented product in the order you want it picked.
Some products fit the mold (food, perishables, some electronics, medicines and many other retail goods), while other types of inventory are more about storage density and efficiency. Pick modules help you find solutions to items that either require FIFO rotation, or need high density storage, or both.
Read more: First-In, First-Out Storage Considerations
- You can mix storage options within a pick module: FIFO flow racks with LIFO pallet storage can both feed a picking platform
- First-in, first-out systems make inventory more visible and play well with technologies like light-directed picking
Save space. Serious space
In a pallet picking operation, you'll save at least 35% in a typical 6-deep application. If you're picking from cartons or totes, the savings are even better compared to shelving. These space savings can delay or eliminate expensive reolocations or the need for wholesale redesign because pick modules free floor space to other uses. The more vertical cube you can utilize, the more space you'll save.
Read more: How to Measure and Improve Industrial Storage Space Efficiency
- Because pick modules centralize high-throughput SKUs in compact, dedicated zones, you can shrink peripheral racks and aisles
- Instead of single-deep selective racks, deep flow lanes let multiple units of the same SKU to be stored behind one another, reducing the number of required aisles
Pick modules help workers spend more time on task, less on walking and transit
When you concentrate storage into smaller areas and picking operations, you eliminate nonproductive "walk" time. Order pickers are picking - not walking - for more hours every day. They can reach everything easier and faster. This lets you reduce the amount of time people spend searching, recalling storage positions and walking. When people can reach things faster, they get more done.
Read more: When it Comes to Order Picking, Don't Walk the Walk
- Transit time kills productivity. People who move around less accomplish more in place. Imagine working a desk job and needing to move away from your desk scores of times a day to get things done
- Less walking = better accuracy. It lets people focus on the job, not the trip between picking locations. Even if you aren't eliminating movement, reducing it is highly productive
- Optimizing movement reduces operating costs. Wasted motion is wasted time, dollars and focus
Replenish your inventory faster easier than ever
Because you're concentrating picking operations, you can focus inventory, whether pallets or cartons, into your system at the right place and time for maximum productivity and control.
Video: Adapting to Product and Inventory Changes
- Due to separated loading and picking aisles, simultaneous replenishment and picking occurs without interference
- FIFO replenishment is largely "back-to-front" and hands-off
- Conveyor integrations reduce manual handoffs and touches, speeds transfers, and reduces buffer point queues
- High-velocity SKUs can be centralized inside the module
- Barcodes, pick-to-light or sensor feedback corrects picking/replenishment problems
Pick modules can be the best choice for high-volume, high throughput distribution center operations
But simpler, smaller-scale picking operations can benefit from the versatility and efficiencies created by installing a pick module that consolidates space and operations.
Take a look at your facilities - imagine consolidating picking areas that sprawl across your facility into half (or less) the space, and actually improving your performance. The good thing is, this isn't a high-tech or overly complex concept. WMS (Warehouse Management Systems) automation can play as big or small a part as needed - or no part at all.
Ready to explore your options?
You can leverage Cisco-Eagle's long experience and detailed understanding of these systems to help you identify, specify and implement the right system for you. Contact us today to get started.