Features/Benefits Provided: Doubled monthly order picking capabilities Increased efficiency, throughput and inventory/distribution control Reduced theft and loss Improved ergonomics and provided a clean, well-organized work space

A distributor of medical and health-related supplies distributes products from its 50,000 square foot facility. Pallet rack and a stationary shelving system were used for storage and employees spent long periods of time searching for items to fill orders. They needed a new system to increase productivity and decrease labor costs.

An order processing system was designed and integrated, which consisted of 4 horizontal carousels, an ergonomic workstation, 2 vertical light trees, a sortation light bar at each picking "pod," and interface software.

With the new system in place, a team of 3 full-time workers and one part-time worker are able to ship orders efficiently and accurately. Pickers no longer traverse through a system of stationary shelves and pallet racks to find supplies; the horizontal carousel system presents items to the pickers and eliminates the time previously spent walking and searching for items.

Eighty percent of the company's orders are filled from the horizontal carousels. Operators can now pick 4-5 lines per minute or an average of over 250 lines per hour - a four fold increase over the previous picking rate. Operators are able to batch pick up to eight orders simultaneously; the user friendly vertical light trees direct the picking activity while a horizontal batch sortation bar indicates the quantity and order associated with each pick. This speeds up the picking process and keeps orders error free.

The software, based on a Windows platform, seamlessly interfaces with the company's host software. Workers easily navigate through the interface to set up system operation and monitor productivity.

The systems goal of 40,000 picks per month to 80,000 per month was achieved. The new system also expects to cut down on unnecessary supply consumption by 5 to 10 percent over the coming year.

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