Case Pick Systems
Dematic case picking systems manage order fulfillment tasks, synchronize material flow, supply ergonomic work environments, and provide visibility and insight into operations.
Note: The selections listed on this page are ordered from simpler systems to progressively more automated systems.
The Dematic Case Pick System for Route Delivery using Voice-Directed Equipment and pallet trucks is an order fulfillment system for building mixed case pallets. Headsets provide verbal instructions (including location and case pick quantity) to operators who then pick the case(s) from flow racks, pallet racks, or floor locations and transfer them to pallet trucks.
Challenges
- Inefficient workflows
- Accuracy
- Increase pick rates
Solution
- Warehouse execution system (WES) software
- Interface to host
- Optimized case pick for route delivery
- Case pick to pallet trucks
- Voice directed with route and stop labels
- Reverse route truck loading
Results
- 10% to 30% less time to process orders
- 10% to 50% higher pick rates
- 10% to 30% accuracy increase, voice directed
- Route based delivery
- Visibility and insight into operations
The Dematic Case Pick System for Route Delivery using Convey and Sort is an order fulfillment system for direct-to-store delivery of mixed case pallets. The system builds pallets following logistics rules such as “heavy on bottom, crushable on top” as well as by route and stop sequence.
Challenges
- Inefficient workflows, accuracy
- Congestion, lack of space
- Growth, long work shift
Solution
- Warehouse execution system (WES) software
- Optimized sequencing for route delivery
- Interface to host
- Three-level case pick module
- Case pick to conveyor
- Voice-directed with route and stop labels
- Sort by label-directed pallet building (route and stop)
Results
- Process improvement, reduce cost to operate
- Route-based direct-to-store delivery
- Ship 10,000 to 20,000 cases/shift
- Lot tracking, improved accuracy and productivity
- Compact footprint
The Dematic Case Pick System for Route Delivery using Variable Pick Face Slotting is an order fulfillment system for building mixed case pallets. An automated storage sub-system stores cases of inventory and dynamically replenishes the pick faces based on demand.
Challenges
- Inefficient picking of low-velocity inventory
- Long pick paths
- Inefficient manual pick-face replenishment
- Lack of warehouse space
Solution
- High-density automated storage
- Inbound decant to tote
- Pick to pallet or conveyor, light or voice directed
- Automatic pick-face replenishment of active SKUs
- Execution software synchronizes workflows
- WMS interface
Results
(compared to person-to-goods fulfillment)
- 65% to 80% reduction in pick path length
- 20% to 30% less staff
- 50% to 75% smaller footprint
- 25% to 50% less time to process orders
- Eliminates pick face replenishment, slotting, re-slotting
- Real-time control and visibility into operations
- Efficient storage and picking of low velocity inventory
The Dematic Case Pick System for Route Delivery using Convey and Sort for Beverage Distributors is an order fulfillment system for building mixed cases specifically for beverage distributors. Orders are picked in waves. Completed cases fill conveyor lanes up to the merge. The merge lanes release in sequence to sorter, which sorts the cases for outbound shipping.
Challenges
- Order pick in sequence for route delivery
- Inefficient workflows, accuracy, space
- Throughput and capacity
Solution
- Interface to host
- Warehouse execution system (WES) software
- Wave management and planning
- Case pick to conveyor, route and stop labels
- Voice-directed bottle pick
- Conveyor merge release control by wave
- UPC scan verification
- Reverse route truck loading
Results
(compared to case pick to pallet truck)
- 20% to 40% increase throughput and capacity
- 10% to 30% less time to process orders
- 10% to 50% higher pick rates
- 10% to 30% accuracy increase
- Efficient route-based delivery
- Visibility and insight into operations
- Reduce space required and cost to operate
The Dematic Case Pick System for Retail Store Replenishment is an order fulfillment system using convey and sort with multi-level pick modules for growing operations that need to maximize store replenishment productivity. The system features light-directed picking, convey and sort capabilities, high pick accuracy, and consistently predictable results. Mixed case pallets are assembled manually. Semi-automated and automated palletizing options may be included.
Challenges
- Upgrade case pick-to-pallet truck method
- Maximize store replenishment productivity
- Accommodate growth
Solution
- Case pick to conveyor to palletizer
- Multi-level case pick module
- Light-directed case picking
- Case merge, scan and sort
- Manual palletizing at outbound shipping
- Execution software synchronizes workflows
- WMS interface
Results
(compared to case pick to pallet truck)
- 25% less staff with automated transport & sort
- 25% less footprint
- 10% to 15% increase in accuracy
- 25% to 40% less time to process orders
- 10% to 100% increase in capacity
- Real-time control and visibility into operations
The Dematic Case Pick System with Automatic Replenishment uses the pick-to-conveyor method to fulfill orders. Operators pick cases from pallets in a rack structure and place them onto a conveyor that flows to a sorter, which sorts the cases for outbound shipping. An automated storage and retrieval sub-system (AS/RS) replenishes inventory pallets to the rack structure. Pallet replenishment is accomplished using automated storage machines.
Challenges
- Inefficient manual replenishment
- Lack of warehouse space
- Wide replenishment aisles
- Picking and inventory management accuracy
- Need for strategic SKU slotting
Solution
- Multi-level pick modules
- High-density, controlled access pallet storage
- Case pick to conveyor, light or voice directed
- Automated storage machine, pick face replenishment
- Mixed-case palletizing
- Software directed, real-time control
- Execution software synchronizes replenishment
- WMS interface
Results
(compared manually accessed pallet rack)
- 20% to 30% less staff
- 50% to 100% smaller footprint
- 10% to 20% increase in accuracy
- 25% to 50% less time to replenish pick faces
- Real-time control and visibility into operations
The Dematic Automated Case Pick System for Route Delivery is an order fulfillment system for automatically building mixed cases specifically for beverage distributors. The system is ideal for low velocity inventory. Full pallets are de-palletized to the case level, stored, retrieved, and then combined with high velocity inventory for outbound route delivery.
Challenges
- Inefficient picking of low-velocity inventory
- Long pick paths
- Inefficient manual pick face replenishment
- Lack of warehouse space
Solution
- Case-to-person order fulfillment
- Case pick from pallet workstations
- High-density automated pallet storage
- Pallet store, retrieve, case pick, outbound
- Execution software synchronizes workflows
- WMS interface
Results
(compared to traditional case pick process)
- Delivery drivers eliminate order picking on truck
- 10% to 20% reduction in route truck stops
- 20% to 30% less staff
- 25% to 50% smaller footprint
- 25% to 50% less time to process orders
- Eliminates low-velocity pick face replenishment, slotting, re-slotting
- Synchronized pick process for slow, medium, and high velocity inventory
The Dematic Automated Case Pick System for Meat Protein manages the specific order fulfillment requirements of harvest operations and display-case ready/portion-pack facilities that supply wholesalers, retail stores, food service companies, and export companies. The system supports put-away, storage, buffering, sorting, sequencing, picking, palletizing, and reverse-route trailer loading.
Challenges
- Complex manual processes, harsh environment
- Misplaced inventory, FEFO management
- Order processing time, space, accuracy
Solution
- Warehouse execution system (WES) software
- Order planning
- Interface to host
- Automated storage, freezer
- Automated picking
- Manual palletizing (optional robotic palletizing)
Results
- Reduced cost to operate
- High-density storage
- Minimize labor in cold environment
- Lot tracking
- Improved accuracy and productivity
- Automated case sequencer, sorter, and buffer
The Dematic Automated Case Pick System for General Merchandise is an order fulfillment system for automatically building mixed cases specifically for general merchandise retailers. The system is ideal for replenishing distribution centers or retail stores.
Challenges
- Inefficient case storage
- Manual case picking
- Throughput capacity
Solution
- Warehouse execution system (WES) software
- Order planning
- Interface to host
- Automated picking with Dematic Multishuttle
- Conveyor network
- Manual palletizing workstations
Results
- Reduced cost to operate
- High-density storage, compact
- Reduced labor
- Lot tracking for improved accuracy and productivity
The Dematic Automated Case Pick System for Industrial Supplies is an order fulfillment system specifically for industrial supply distributors. The system automatically builds and stores mixed case pallets in an automated storage and retrieval sub-system (AS/RS). It is also a goods-to-person piece and case picking system for outbound loads.
Challenges
- Lack of warehouse space
- Manual case pick to pallet trucks
- Labor costs, availability, skills
- Picking and inventory management accuracy
Solution
- Goods-to-person order fulfillment
- High-density automated storage
- Inbound decant, pick, pack, outbound sort
- Execution software synchronizes workflows
- WMS interface
Results
(compared to person-to-goods fulfillment)
- 40% to 70% less staff
- 25% to 60% less footprint
- 10% to 30% increase in accuracy
- 25% to 50% less time to process orders
- Eliminates pick face replenishment, slotting, re-slotting
- Eliminates long pick paths through the facility
- Real-time control and visibility into operations