Features/Benefits Provided: 100% increase in productivity No reading, writing, or searching Errors reduced by 90% Eliminated substitutions and skipped items Reduced labor costs

A distributor of fundraising products to schools, associations, and non-profit groups was experiencing new growth due to consolidation in the industry. Because of their strong industry position, catalog selections had grown from 20 to 230 items in recent years and they were not only filling their own orders, but had also become a fulfillment center for other fundraising companies. In addition, each year they source, hire and train a large temporary staff for a short peak season. From October 1st to December 15th, fulfillment demands were intense, associated costs were very high, and employee turnover was significant. They needed to find a more effective and efficient picking system to meet these new business challenges.

To respond quickly, the company planned a new distribution center and reviewed order fulfillment techniques. They needed to improve picking accuracy while doubling their current rates and cutting employee requirements in half. A thorough technology investigation led them to a light directed picking system utilizing wireless technology.

The company uses 2 zones per order, with 1 person per zone, each running 3 lines. The bar code on the order is scanned using an RF scanner and the digital displays light up, indicating the quantity to pick.

Beginning with zone 1, the item is picked and then the button on the digital display is pushed to complete the pick.

When all items are picked in zone 1, the bay controller shows that all picks are completed in that zone.

The order is then moved by conveyor to begin the same process in zone 2 to complete the order.

The pick to light system has made a world of difference. Employee turnover has dropped, pick accuracy has increased 100%, productivity has more than doubled, and their per capita capacity to fulfill orders during peak season has increased by more than 200%.

 
is a proud member of Order Fulfillment Council, a Council of the Material Handling Industry of America

P.O. Box 1608
90 Alfred Plourde Parkway
Tel: (888) 233-6796
Fax: (207) 786-0271
Email: info@diamondphoenix.com
Website: www.diamondphoenix.com