Warehouses or distribution and fulfillment centers use a variety of methods to pick stock from shelves and get it to the shipping department. One
such method is called Pick Module.
A Pick Module features order pickers who pick products from full cases or individual items from broken or split cases and place them in a tote or directly onto a conveyor that carries the collection of products to the shipping area.
The concept uses a variety of technologies to direct workers to the proper shelf to complete a pick. These technologies include pick to lights, voice pick or a paper pick ticket.
It is also typical in such a pick arrangement for a worker to be assigned a specific zone or location within the pick module where he or she is responsible for performing the picking of SKUs.
Once the picks are transported by tote or conveyor to a shipping area, the products are consolidated and prepared for loading onto outbound trucks. If a tote carries items picked from many different zones, but the collection is all part of one order, then the conveyor and order-picking system typically features special technologies to direct the totes to each zone within the pick module.
Many things must be considered when creating a pick module.
· The structure of the module. Keep in mind that there are a number of configurations in which a pick module can be constructed. There are single level or multi-level pick modules that integrate pallet racks, shelving or free standing mezzanines into the structure. Products are stored in various manners inside the module including by pallet or carton flow racks, selective racks, shelving and push back racks.
· What type of storage medium to use. The storage medium chosen for a pick module is determined by an analysis of the history of the SKU order line and the actual size of the SKU.
· Picking technology. An assortment of picking aids and technologies are available to integrate into a pick module to ensure efficient results. These include pick to lights, voice directed picking, radio frequency (RF) picking and paper picking. Each technology has its own advantages and disadvantages that need to be carefully considered when constructing the pick module.
· Method of picking. There are a number of picking alternatives a warehouse can select to use within a pick module ranging from the most basic and widely used discrete order picking to zone picking and wave picking. Moreover, methods are often combined to take advantage of individual benefits.
Warehouses that use Pick Modules believe that the concept helps to perform picks efficiently as it saves space. Many warehouse executives like the
versatility of the concept and the fact that high-density pick modules can be scaled to the need.
Typically, Pick Modules are multi-level and operate by offering optimum flow efficiency. For example, gravity moves palletized loads through the system as well as technologies integrated with conveyor and sortation systems direct the flow of in-bound products.
An example of a Pick Module is a Pallet Flow Rack. This is a method of moving full loads of pallets and can be combined with carton flow or standard pallet racking.
Such a Pick Module uses skate wheels as well as gravity to minimize an employee’s workload and keeps picking positions stocked throughout all levels of the module. Pallets can be placed at different levels within a Pick Module System ready to flow to worker concentrated areas via conveyors.
The Pick Module is constructed of sturdy side rails that provide support for the pallet rack system. Pneumatic or hydraulic braking systems are often incorporated into the Pick Module providing extra depth and permitting pallets to be stored up to 20 deep.
One company that offers a variety of Pick Modules is UNARCO Material Handling, Inc., headquartered in Springfield, Tennessee. Its product assortment includes carton flow, pallet flow, push back rack, drive in rack, pick modules, and cantilever rack. Its website provides detailed information on the benefits of Pick Modules and includes details of the various types of Pick Modules available. The site also offers a large assortment of photographs of various Pick Modules and flow configurations.
Photos used to illustrate this article are courtesy of UNARCO.