Overview
The Dematic Batch Pick and Consolidate High-Rate Piece Pick System is ideal for operations with high-end order volume rates. Operators use pickcarts to pick items for multiple orders in a single pass and a crossbelt sorter consolidates the orders. The system de-constructs and re-constructs orders to create an ultra-efficient order fulfillment process.
The system is efficient for customer-direct fulfillment and retail store replenishment operations that need to process a large quantity of orders (high rate). It is ideal for retailers and wholesalers of apparel, office supplies, personal care products, general merchandise, pharmaceuticals, as well as industrial supplies, replacement parts, and hardware.
Benefits
- Process improvements for optimized pick operation
- Operational flexibility, scalability
- Improved service levels for responsiveness and cycle time
- Scan validation ensures accuracy and enhances customer goodwill
- Modular design and defined functionality provide consistent, predictable performance
- Visibility and insight of operations
System description
The Dematic Batch Pick and Consolidate High-Rate Piece Pick System has a pre-engineered, standardized design configuration that ensures predictable picking performance. Here is the general order of how the system functions:
- Picking: Workers batch picked items into totes, and conveyor transports the totes to the storage buffer.
- Storage Buffer: The totes are inducted into the automated storage sub-system, which serves as a buffer prior to order consolidation. In addition, the system is an active pick location for inventory required to fill orders.
- Order Consolidation: The totes are transports to induction workstations where workers remove the contents and induct them onto the crossbelt sorter, which consolidates the order.
- Packing: When the crossbelt sorter has sent all items for an order to a packing workstation, a worker packs and releases the order for shipment.
System management
The Dematic Warehouse Execution System (WES) software manages a continuous flow of orders for processing downloaded from the Warehouse Management System (WMS). The WMS is responsible for the overall operation of the facility, including inbound receiving and outbound shipping.
The Dematic WES software is a scalable logistics software platform responsible for directing, controlling, and synchronizing workflows. It dynamically manages processes, inventory, workforce, and material handling automation in real time.
Order processing strategy can be wave based (typical for store replenishment) or waveless continuous flow (typical for customer-direct e-commerce fulfillment).
The Dematic WES software includes supervisor interface screens such as global view of picking, sorter performance, buffer status, system progress, order information, picks per operator, total picks, and items packed.
Warehouse Management System (Host)
- Order entry
- Inventory control
Fulfillment orders
Status and completion
Dematic Warehouse Management System
- Batch wave planning
- Waveless continuous flow
- Order management and execution
- Order attributes, priority, changes
- Direct piece picking
- Scan and sort control
- Balance workflow
- Visibility and insight
Comparison
The Dematic Batch Pick and Consolidate High-Rate Piece Pick System is more accurate, requires less labor to operate, and is more efficient than discrete pick and pack systems.
| Discrete Pick and Pack System | Batch Pick and Consolidate System |
| Manual operation throughout: replenishment, picking, transport | Automated, real-time control, visibility and insight into operations |
| Discrete order picking | Batch order picking |
| Manual sort and put to order container | Automated sort to packing workstation |
| Buffer not included | Automated storage buffer prior to automated sort |
| Limiting throughput and capacity | High throughput and large capacity |
| Manual transport between processes | Conveyor connects processes |
| Transfer order items to shipping container and pack at end of process | Integrated order consolidation and packing |