SPLIT CASE TECHNOLOGIES & USES Split Case Order Picking Technologies & Systems
Slow Medium
A-Frames Floor Robots Horizontal Carousels Mini-Loads ASRS
x
x
x
x
Shuttle Technologies Vertical Carousels Vertical Lift Modules
Storage Density
Fast
Lines/Hours
Lines/Hours
x
4200/orders
x
Pick-to-Light Flow Rack Robotic Carousel Systems
Throughput
Velocity
x
x
x
x
x
x
x
x
x
x
x
x
there may be more than one possible solution, and the best solution is often a blend of two or more technologies.
DETERMINING THE BEST SOLUTIONS A-Frame: An A-Frame is an automated dispensing/picking system used for high speed split case order picking. It can be configured in a Pick-to-Belt, Pick-to-Tote or Pick-to-Shipper mode to suit a wide range of customer requirements for split case order picking. In its Pick-to-Tote configuration, the A-Frame system can handle up to 4,200 orders per hour (the number of lines per order is almost irrelevant). The system requires no labor, other than replenishment. Portable models are available to meet smaller scale, promotional or seasonal order fulfillment demands. Floor Robots: Floor robots pick up and deliver stored items on portable storage shelving to an operator, who then picks the required item. The robot then returns the unit to storage. Throughput rates range from 100 to 450 lines per hour/per operator. This system offers good storage density, and capacity can be increased by adding robots. Programming, equipment and ongoing maintenance costs make these systems expensive. Horizontal Carousels: Horizontal carousels are a series of bins that rotate horizontally around an oval track, delivering
Accuracy Levels
Labor Savings
Cost of Ownership
Characteristics
1 = Worst to 5 = Best
2
5
5
$$
High speed fully automated order fulfillment that requires zero picking labor. Portable and larger systems available. Piece weight limited to <1 lbs.
100-450
3
4
3
$$$$
Able to expand the system very quickly in a short period of time
150-550
4
4
4
$$
Cost effective batch picking, unique advantage for fewer lines per order profiles
60-100
4
4
4
$$$
Very large number of SKUs with moderate throughput expectations
100-250
4
4
3
$
Large quantity of high velocity products with small to medium physical characteristics
200-700
4
4
4
$$
Cost effective means of picking large quantities of SKUs in a limited footprint
200-700
3
4
4
$$$
Handles extremely large quantities of slow, medium and fast moving inventory
100-275
5
3
3
$
Ideal for very small item inventory and the density it provides
125-375
5
3
4
$
Automatically adjusts storage capacity for very dense storage. Great ergonomics
the stored item to the operator. They are designed for picking slow to medium moving items and cases, with throughput rates from 150 to 550 lines per hour/per operator. Horizontal carousels are commonly integrated in multiple units in a pod or workstation to enhance productivity and throughput. They offer good storage density at relatively low cost. Mini-Load System: This system handles slow moving smaller sized inventory from 100 to 250 pounds, stored in trays, totes or cases. It is optimized for high density storage with throughput rates ranging from 60 to 100 lines per hour. Pick-to-Light Flow Rack: Sections of gravity flow rack are used to queue fast moving inventory. A light display ranging from a simple â&#x20AC;&#x153;gumballâ&#x20AC;? to alphanumeric displays indicates to the picker which SKU and what quantity needs to be picked. This system allows one operator to replenish inventory from the back while the other operator is simultaneously picking. Carts or conveyor is used to transport the orders from one bay or zone to another. Robotic Carousel Systems: These systems use a robotic extractor to retrieve items or totes as they are queued in horizontal carousels. A single robotic extractor can service three horizontal carousel units stacked in a tier, selecting the required items from one unit while the other two po-
sition for the next picks. These systems offer very good storage density with throughput rates from 200 to 700 lines per hour/ per operator. They are cost effective for handling small, medium and large quantities of slow to medium moving items. Shuttle Technology: Shuttle technology is used for the buffering, sequencing and picking of items stored in plastic totes or cartons weighing under 125 pounds. Shuttles travel on rails at each storage level and are equipped with inserter/ extractor devices that remove/replace stored items. These systems are expensive; however, they handle large quantities of inventory at throughput rates of 200 to 700 items per hour. Vertical Carousels: Vertical carousels are cost-effective, self-contained systems of shelves or carriers that rotate vertically. Stored items are presented to an operator at an ergonomically optimal height. They provide high storage density and are designed for small item order picking of slow to medium moving inventory. Throughput rates range from 100 to 275 lines per hour/per operator. Vertical Lift Modules (VLMs): This cost effective system offers excellent space utilization and storage density. Slow and medium moving items or cases are stored in columns of trays in the front and back of the unit, accessed by an automatic insert-
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