Case Study Order Picking
use of paper picking lists, a labour- intensive and error-prone method. TopPak soon identified that there had to be a faster and more accu- rate order assembly tool available. This resulted in the implementation of the Pcdata pick-to-light system. “Pick-to-light picking is the optimal method for this operation, with relatively little article numbers and a large number of order lines,” says Nanne van der Burg (pictured), TopPak’s director of operations.
“Pick-to-light
light displays of Pcdata can be installed, as easily as Lego is clicked, on the rail mounted to the flowrack. After that, they work immediately.”
picking is the optimal method for this
operation, with relatively little article numbers and a large number of order lines”
The 140 pick locations within the pick- to-light system are split over two levels – the upper level for item picking and the lower level for case picking. To facilitate this approach, all 60 articles have dual locations, one with open boxes and the other with ready-to-pick cartons. Between the two levels, a pick-to-light rail is installed with a display for each SKU. An aluminium guide rail runs adjacent to the pick locations, allowing boxes to be effortlessly transported from one end of the picking area to the other. System installation was accom- plished quickly with no operational impact. “In two days, the system was intact,” says Nanne van der Burg. “The pick-to-
MORE PACE, MORE PEACE
In this part of its operation, TopPak typi- cally uses seven operatives, who manage the process from order induction to picking through to packing and shipping boxes. Since the introduction of the pick-to-light system, productivity has more than doubled. “There is now much more peace in the operation,” says Roland Koch, team leader of TopPak. “Previously our peo- ple walked with their index finger on the pick lists along the pick locations. This is much easier to work with.” While using paper, 10% of all orders ended up with a mistake of some kind.
www.shdlogistics.com
Not only did this have a negative impact on customer satisfaction, but to combat this problem, a quality control step had to be built into the process, to ensure that errors were correctly picked and packed. The error rate with pick-to-light is now so low that a simple count of outbound boxes is the only QC step required. “Our client has agreed that we check 5% of the outbound orders,” says Roland Koch. “In the previous half year there we no errors found. “Top-Pak is extremely satisfied with the pick-to-light system supplied by Pcdata. It is an efficient and robust system that delivers enhanced productivity and flexibility.” n
www.pcdata.nl Storage Handling Distribution July 2012 25
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