Order Picking and Fulfillment Systems Design

There are several items to give consideration to when designing an order picking / order fulfillment system.  The first step is a Product Slotting Analysis which will determine how much of each SKU will be stored in each type of available storage equipment (shelving, flow racks, carousels, rack etc.).  Typically, an efficient forward pick area consists of a mixture of the different storage equipment in order to have the most cost effective and efficient system design.

Performing a Needs Analysis is the second step of the process.  Here is where you adapt material handling best practices with the unique needs associated with your operation.  What provisions need to be made for seasonality or introduction of new product?  What is the profile of orders placed per day?  How much time is available to process your orders?  When do orders have to go out the door?  What are your growth plans for the next 5 years?  These are just a few of the questions that lead to a successful design unique to your business.

Once you have decided on your Order Picking Method and system layout, you then have to determine how you are going to assign work to the order pickers.  Should you consider using a high technology solution to your order picking process such as wave management software, pick-to-light or voice-directed picking in order to give your operation the competitive edge over those still using a paper based system? 

One of the goals in your system design should be to eliminate as many product touches as possible.  Conveyor systems that bring product from the order picking area to other areas such as quality control, packing operations and the use of sortation systems to facilitate getting orders to the right door for shipment all play a vital role in reducing the costs associated with order fulfillment.

Designing an order picking / fulfillment system requires significant effort, but the rewards associated with this process include getting control of labor costs, maximizing productivity and improving order accuracy.  All of these rewards lead to happier customers and are well worth the effort.

TriFactor offers facility design layout services for those companies in the planning stages for the construction of a new storage facility or the reconfiguration of their existing operations.  Our engineers collaborate with architecture or construction firms to determine the proper pallet rack configuration when developing the overall warehouse and production layout and design.  Regardless of the material handling situation, TriFactor has developed a solution process over the past 20 years which is now called the TriFactor Edge.  If you’re looking for an Edge on your competition, call TriFactor today at 1-800-507-4209 to get us started solving your warehouse and distribution center needs.

For additional information on Product Slotting, Distribution Center Planning, Choosing a Conveyor System and other material handling solutions go to the TriFactor Learning Center.  TriFactor’s Richard Gillespie wrote a white paper titled “Critical Factors when Choosing and Order Picking System” which goes into greater detail on this subject.