Overview
The Dematic Zone Route Piece Pick System uses conveyor network to route order containers through zones with specific SKU categories. When a container (typically cardboard boxes) enters a zone, operators pick items and place them in the container. The containers only go to zones with picks. The system supports operations that need to pick, pack, and ship orders quickly and accurately.
The system brings productivity and processing speed to the order fulfillment operation. Using pre-engineered and pre-configured modules, it streamlines the piece picking environment by automating the flow of order containers. The system works best when the majority of orders processed require the order containers to travel to 50% or less of the pick zones.
Benefits
- Process improvement, synchronized pick, and pack and ship
- Eliminate long pick paths through warehouse
- Transport inbound inventory for re-stocking zones
- Increased throughput rates
- Improved worker ergonomics
- Real-time control, visibility, and insight of operations
System description
The Dematic Zone Route Piece Pick System has a pre-engineered, standardized design configuration that ensures predictable order picking performance.
The system is a discrete order pick system for distribution operations that need to pick, pack, and ship orders more productively, accurately, and quickly. The pre-engineered zone route process arranges the warehouse into pick zones — each pick zone may support a specific SKU category or velocity.
The layout typically includes 4 to 16 picking zones. The system brings order containers to the picking zones. Operators remain in an assigned zone and do not roam the warehouse searching for picks. Instead, they focus on picking specific inventory in a small area.
In each zone, SKUs are staged on flow rack, shelving, or pallets. The zones are slotted based on family groups, velocity, or cube utilization. The system routes order container only to the zones where there are picks.
System management
The Dematic Warehouse Execution System (WES) software manages the automated operation of the entire zone route conveyor network. The Dematic WES software directs the flow of order containers into the appropriate pick zones. Using data from the barcode scanners, the software actives the right-angle transfer devices allowing containers to automatically divert into pick zones.
Dematic WES software directs picking by lights, voice, or RF devices. It also directs the operation and control of the packing workstations and shipping sorter sub-system. Real-time information is available regarding container location, divert/sort statistics, barcode read rates, and container re-circulation. A graphic of the system layout displays real-time information about the status and performance attributes of each sub-system: conveyor network, picking, packing, and shipping sorter.
The Dematic WES software can accept orders from the WMS in multiple ways, but typically as discrete orders. The Dematic WES software includes supervisor interface screens to provide a global view of picking, pick performance, system progress, order information, picks per operator, and total picks.
Warehouse Management System (Host)
- Order entry
- Inventory
Fulfillment orders
Status and completion
Dematic Warehouse Execution System
- Interface to host
- Order management and execution
- Order attributes, priority, changes
- Synchronize and optimize processes
- Direct piece and case picking
- Scan and sort control
- Order status query
- Visibility and insight
Comparison
Dematic piece picking systems are more accurate, require less labor to operate, and use less warehouse space than conventional piece picking systems.
| Conventional Piece Pick | Zone Route – Order Container to Zone System |
| Manual process for replenishment, pick, pack, sort, and ship | Execution software synchronizes pick, pack, sort, and ship workflows |
| Separate processes | Integrated system from receiving to shipping |
| Manual transport of order container | Automated convey/sort of order container |
| Non-strategic picking | Strategic picking |
| Long pick path | Compact pick zones result in less walking |
| All manual processes | Automated transport/sort, in-line scale, label print and apply |
| Less throughput capacity | More throughput capacity |
| Manual transport of inventory re-stocking | Transports inbound inventory for re-stocking zones |
| Limited visibility into system status | Visibility and insight into system status |