Order make up

Today, the execution of orders is one of the most delicate strategic points and, in the logistic process represents one of the best chances to improve the competitiveness of the enterprises. The market demands a greater splitting (small quantities) and more frequent shipments of the orders thus forcing to obtain a high level of service and security (no picking errors and on time deliveries). This trend, if not inserted into a precise management, may cause a considerable increase in costs often accompanied by unacceptable error rates.

A univocal solution valid for all the company realities does not exist, it is necessary to study the most suitable method by considering:

• quantity of managed references
• size of each single reference
• quantity of references by rotation class (A/B/C)
• number of orders/day and seasonability
• average number of lines/order and pieces/line
• delivery time to be ensured

Hereinafter, the possible solutions seen in a precise context are described, which will have to be adapted to the single realities and, if needed, assessed according to mix conditions.

• Picking with R.F. terminals

It is the most classical picking system that operates by single order automating the widespread picking by paper list. Typically, an order is assigned to an operator who picks it from the first to the last line.

• Pick to light

This picking system allows obtaining the highest productivity rate. Each item is equipped with a light point that switches on to show the picking and the quantity on a display. The system is combined with dynamic shelves having several accumulation points.

• Pick to belt

This picking system is suited to pick entire packages or bulky items.
A central conveyance line is used to transport the packages directly to the delivery where they are palletized or otherwise prepared for shipment.

• Massive Picking
  

When there are very split orders it can be useful to pick groups of united orders. In this case the summation of items having the same code in the group of accumulated orders (f. ex. 50) is picked for each reference. Obviously, a sorting is required at the delivery and therefore, this phase needs to be automated with the necessary equipment: Sortech, Boxtech, Wintech.

Sortech

A linear plate sorting system with 1 or 2 fronts used to sort parcels/envelopes/packages up to 5 kg with max 50 deliveries for single front unloading system and max. 40+40 for two front unloading system.

• by small packages or boxes already packed: sorting by delivery destination (geographical area, carrier, etc.)
• by order, where one operates by sorting the different picked products in a cumulative form on the individual orders to make up the order quickly and simultaneously

The choice must be made taking into consideration the recovery of efficiency on picking.
It uses a plate system (trays hooked to a central driving chain), which transports the product along the delivery bays (sorting) and releases it near the corresponding destination chute (area, order, carrier, etc.). The product can be either loaded on the plate directly by the operator or by means of one or more controlled conveyor belts.

Sortech is a modular system that offers the following solutions:

• sorting on a variable number of deliveries, max 50 for single front system, max. 40+40 for a two front unloading system
• variable travelling speed depending on the requirements (max 20 m/min.- 60 pieces/min.)
• integration with internal handling lines and warehouse management systems (EASYSTOR) or transport management (DELSY)

Boxtech

For small orders and limited cumulation (32) one can use one or more Boxtech modules. It is a bay system combined with a quick pick module that in this case operates like a put to light system.

• The operator reads the product code, each box is connected to an order and the module display shows where (shelf, roll-container, stender, pallet) and in which quantity the product must be placed
• Boxtech is a very flexible, moderately priced tool
• Windtech is a special version of Boxtech
  
  

Special solutions

In the field of order preparation there is a great variety of applications depending on the requirements of the single enterprises. Some special applications may offer the occasion for consideration:

• Serviced Stock

The companies that operate with a high service level on the market and require flexibility and a strict cost control may expand the service stock and let the batches of massive orders be picked by the logistic operator.

• Massive optimisation

Another interesting solution of picking of a high number of references can be obtained by automating the pallet area with picking control using the Quick Pick system.

• Mix of techniques

In big distribution centres the use of mixed techniques according to the product classes could be economically profitable.

• Automatic vertical warehouses

Rotating warehouses or mini loaders can be used for some application, especially where there is a room shortage.

• Shift warehouses

They are used for high volume/weight products that require low handling.

• Linear sorters

Automatic sorting systems for medium size packages are realised to produce 3000, 6000 and 10000 pieces/h.