Small To Medium Size Sku Manual Pick & Sort Concepts

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A well-designed put wall can be integrated to serve as the principal system for accomplishing the secondary sort. Secondary sort at the put wall The secondary sort takes place immediately at the destination of the sorter in a way that facilitates an efficient and ergonomically optimal packing process.

The Principles of Material Handling

A wall of cubby holes is placed alongside the sorter, with a narrow aisle between the chute face and shelves. An operator roves back and forth, picking units from the chute and scanning barcodes. A put-to-light PTL display will indicate in which cubby items must be placed. The sorter control system will attempt to discharge a unit closest to its final put-wall destination. If that destination is blocked, another chute in this segment may be used. Performing the secondary sort at the chutes vastly increases the possible pick wave size.

The put system can be designed with different size cubbies, allowing the sorter control system to pick the appropriate destination for a given order size. On the pack side of the wall, the PTL system lights up the cubby for completed orders one at a time.

Retailer's Guide to Processing Incoming Freight

If necessary, several lights can be lit if the order is too big for one cubby. The text display at each cubby will convey special handling instructions. Put walls perpendicular to the sorter In this variation of the final sort, put walls are placed perpendicular to the sorter track. The benefit is that the secondary sort system is no longer limited by the track, providing for a larger pick wave. Integrating the final sort in the sorter control system will allow put waves to overlap such that the next put wave will be assigned to a put wall when a certain amount of cubby holes have been assigned and packed out.

It is possible to have the put wave assignment be influenced by the availability of the secondary sort positions such that the put wave assignment becomes continuous and fluid. Latest Products. Latest News Cimcorp unveils newly expanded headquarters. Research from Interact Analysis outlines potential challenges ahead for warehouse automation market.

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What Is Order Picking?

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Order picking is the process of selecting items from a warehouse inventory, to satisfy several independent customer orders. This is an important part of the supply chain process and has been considered the most labor-intensive and expensive activity for every warehouse. Since order picking involves such a high cost and can directly affect customer satisfaction, companies are learning more about improving their processes to create a more efficient supply chain.

There are many different types of picking in a warehouse and each one works as a customized solution for each business. Depending on the size of your warehouse and inventory, the manpower you have on hand, and the number of customer orders made each day, there may be certain methods that are more efficient for you than others. Consider the following types of order picking in the warehouse and learn how you can get quality advice and efficient management of your supply chain so you can focus on growing your business.

The most common type of picking is single order picking. The picker is provided one order at a time and then goes to the warehouse to find each item on the list before completing the order. However, in many cases, the sequence in which orders are given to pickers and the routes they follow are not optimized.


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The worker must always make a full trip through the warehouse just to fill a single order. This is not the most efficient method. Warehouse management systems WMS can help solve this problem and increase productivity.


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In this case, workers can pick multiple orders at a time, with both manual and automated picking. The manual picking environment works by allowing the picker to pick SKUs required for multiple orders at a time. This minimizes the travel time. With automated picking, the worker remains in one location while horizontal and vertical carousels deliver the required SKUs to the worker.

This is the ideal pick and pack solution for cases when multiple smaller orders need to be distributed.

These orders are more effective for workers that travel long distances within a warehouse. Multi-batch picking is used for orders coming from different areas in the warehouse, and thus reduces the order pick times by collecting numerous orders simultaneously. This process also reduces the time needed to process multiple SKUs. This method divides the warehouse into several zones and assigns workers to only work within a specific zone. Each zone can use its own type of technology and storage system, depending on what would work best for the SKUs stored in that zone, and the storage technology used in that zone.

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Orders can be picked in the past from zone to zone, or delivered to a specific point before shipping. This strategy involves passing orders from one zone to another for fulfillment. If an order originates in zone A, a worker adds all the SKUs required from that zone before it passes onto zone B. This is repeated until all the items can be taken to shipping.

To maximize productivity with this method, order management software OMS can be used to manage the order flow.

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This method is an alternative to pick and pack. Each zone selects the SKUs required for the order simultaneously. When all the SKUs are together, the partial orders are matched up into one large order.