CASE STUDY: RF Picking and Fulfillment System

The Problem: Picking to Paper and Manual Pack Stations Inefficient

A manufacturer and distributor of literature, books, CD's, and DVD's needed a turnkey solution that could solve end to end fulfillment needs. Everything from order picking to carrier sortation needed to be addressed.

The Solution: RF Zone Picking, Replenish to Order (RTO), In-Line Manifest, and Sortation System

CASI designed a system that addressed a number of issues that allowed entire operation to function with minimal staff and maintain a solid throughput. The system also addressed needs for full case, piece picking, and low SKU volume issues.

RF and Zone Picking Overview

CASI SolidPack PCs and Symbol RF terminals utilize SolidPick to retrieve order information from Oracle.

Operator prints a licence plate barcode (LPN) that is associated with the order to be fulfilled.

Operator then puts the carton on the conveyor that automatically accumulates and transports empty carton to the picking zones. The shelving shown on the photo above (left side) is a unique feature CASI built called Replenish to Order (RTO). Lower volume SKUs not in flow rack zones are batch picked all at once, loaded to the RTO station, and then enter the ordering queue. This process saves pickers from going through the warehouse for single items and presents these items in a picking zone.

Fixed scanners read the license plate. If there is a pick in that zone, the carton automatically diverts to any of 4 main picking zones where a SKU exists in that zone. The flow rack holds the top 80% of the fast movers over 4 picking zones.

The operator(s) then scans the license plate barcode. The SKUs for that carton in that zone are then presented on the RF terminal. The operator scans each item as he puts it into the carton. The system verifies each SKU for that order is included before it will release back to system. If there is something missing, the carton is again diverted back for QC. User exceptions allow operators to modify if needed. These permissions may be customized per any operational rules or needs such as manager approvals, etc.

After all the zones have cleared, void fill is dispensed and added to the carton. The carton is then pushed through an automatic taper before going to the automatic manifesting area.

After the pick zones clear, open cases are weighed for manifest and verification.

Full case picks are merged after the scale, then transferred to the 24 volt conveyor system with the open case picks.

All cartons are presented the labeling zone. A set of blade stops ensures correct placement of labels. Full cases require only a single label for shipping. All open cases receive a packing list label and a shipping label.

After labels are applied, cartons go around the 90 degree curve to the sortation area. SolidRoute sorts based on carrier, service type, LTL, etc.

Equipment Overview

• TransMaster 9000 Zero Pressure Accumulation conveyor system - 24 volt
• CASI 951 In-Motion Checkweigher
• SortMaster 100 bi-directional diverts
• Datalogic 2400 and 6300 series scanners
• CASI standard print and apply with 24" tamp
• Symbol RF terminals
• SolidSuite WCS modules
  • SolidComm - Oracle host interface
  • SolidRoute - Routing and sortation
  • SolidShip - FedEx direct shipping interface
  • SolidPick - RF picking module and RTO (replenish to order)

Benefits from the new efficiencies

The benefits from the new system include drastic labor savings and significant increases in order picking accuracy. The entire warehouse including management and operators is extremely lean compared to most DC operations.