1st Edition

Eaches or Pieces Order Fulfillment, Design, and Operations Handbook

By David E. Mulcahy Copyright 2007
    948 Pages 229 B/W Illustrations
    by Auerbach Publications

    If your business uses warehouses to deal with the sales of goods, then you know that facility operations, shipping, and customer service are important to your company's health. Eaches or Pieces Order Fulfillment, Design, and Operations Handbook offers insights for warehouse, distribution, or logistics professionals to make their "eaches or pieces" order-fulfillment operation more efficient and cost effective as well as provide better customer service.

    Created for direct marketing and retail store fulfillment operators, this handbook emphasizes the skills and knowledge needed to design, organize, and execute an order-fulfillment operation or concept. The first chapter reviews order-fulfillment activities and distribution operations. The author then proceeds to discuss docking; design parameters; storage; pick, pack, and ship activities; and power stock keeping units (SKUs). The final chapter discusses trash removal, vendor-delivered unit of product (UOP) rework locations and flows, and customer returns.

    Preplanned and organized order-fulfillment operations increase accurate and on-time deliveries, reduce costs, and improve profits. By developing and maintaining an order-fulfillment concept as outlined in Eaches or Pieces Order Fulfillment, Design, and Operations Handbook, you will discover useful strategies for your next warehouse or plant facility as well as improve existing order-fulfillment operations.

    ORDER-FULFILLMENT OBJECTIVE AND THEIR IMPACE ON A COMPANY PROFIT AND CUSTOMER SERVICE
    Introduction
    Overview
    Order-Fulfillment Activities
    Product (UPO) Handling Characteristics
    Order-Fulfillment Operation Objective
    Order-Fulfillment Operation Activities
    How to Project Your Order-Fulfillment Operational Budget
    Why Use Manning or Employee Productivity Schedules
    Why Is High Employee Productivity Important
    RECEIVING, MANIFESTING, LOADING, AND SHIPPING CONCEPTS
    Introduction
    Product Pattern in a Delivery Vehicle
    Options to Improve Dock Area Safety and Efficiency
    Unloading and Loading Concepts
    Customer Order (CO) Carton Dock Sort Concepts
    Receiving and Shipping Dock Interface with an In-House Transport Concept
    MASTER CARTON AND PALLET STORAGE CONCEPTS
    Introduction
    Inventory Control
    Master Carton or Pallet Storage Position Concepts
    Pallet Pick-Up and Delivery (P/D) Stations
    In-House Transport Concepts
    Carton or Pallet Replenishment
    SMALL ITEM AND FLATWEAR APPAREL PICK AND PACK ACTIVITIES
    Introduction
    Protection Concepts for Open Space under an Elevated Pick Position
    Product Movement between an Elevated and Low Level
    Sku Rotation
    Pick Line Profile
    Pick Area Design
    Pick Multiple Small-Item or Flatwear Skus for Customer Orders
    Single Customer Order and One Order Picker or Pick Machine
    Single Customer Order with Multiple Order Pickers or Pick Machines
    Multiple Customer Orders with Multiple Order Pickers/Automatic Pick Machines
    Multiple Customer Orders with a Single Order Picker
    Sortation Location Design Parameters
    Batch Control Release
    Automatic Pick Machine Concept
    SKU Profile or Pick Position Location
    Pick Methodology
    Calculate Your Customer Order Pick Tote or Pick/ Shipping
    Carton Space Requirements
    Pick Zone Length
    Pick Position Objectives
    Pick Position Concept Design Parameters
    Small-Item/Flatwear Pick Positions for a Manual Pick Concept
    Floor Stack Concept
    Shelf Pick Position Concepts
    Pick to Light Pick Position or Location Options
    Push Back Pick Position Concept
    Chute or Slide Pick Position Concept
    Cantilever Rack and Pegboard Pick Position Concept
    Drawer Pick Position Concept
    Stacked Containers Pick Position Concept
    Manual Pick or Order-Fulfillment Concepts
    Pick Position Number Pick Instruction Presentation
    Pick Aisle Identification
    Pick Position Identification Methods
    Pick Position Identification Locations
    Pick Position Identification Size
    Use Alpha Characters or Numeric Digits or Bar Code/RF Tag
    and Sku Description
    Pick Position Identification Methods
    Small-Item Manual Pick Concepts
    Picker Walks to the Pick Position
    Picker Routing Pattern
    Start Pickers in the High-Volume, High-Cube, and Heavyweight Sku Pick Area
    Start Pickers in the Low-Volume, Small-Cube, and Lightweight Sku
    Pick Area
    Pick into a Customer Order Shipping Carton
    Captive Tote
    Customer Order Shipping Carton in a Captive Tote
    Pick/Pack Concept
    Slapper Envelope
    Pick Line Sku Pick Station
    Pick/Pack Line Conveyor Travel Paths
    Customer Pack Slip inside the Carton
    Customer Pack Slip inside a Slapper Envelope
    Picker Carry Single Items Concept
    Manual Pushed Four-Wheel Cart Concept
    Retail Shopping Cart Concept
    Pick Position Elevation
    How to Increase a Picker Reach
    Data Mobile or Pick to Light Cart
    Manual-Powered Pallet Truck or Platform Truck with a Shelf Pick Concept
    Overhead Manual-Powered Trolley with a Basket or Bag Pick Concept
    Mechanized Pick Concept Group
    Employee Ride Powered Vehicles
    Mechanized Stock or Pick Position Is Transferred to the Employee
    Concepts
    Carton AS/RS, Mini-Load or Mini-Stacker Crane
    Carton AS/RS Pick-Up and Delivery (P/D) and Pick Station
    Stacker Crane Concept as a Small-Item Pick Concept
    Stacker Crane Pick Tunnel
    Cartrac Pick Concept
    Automatic Small-Item Pick Group
    Sku Allocation to an Automatic Pick Machine
    Automatic Pick Machine Pick Position Replenishment
    Customer Order Entry and Automatic Pick Machine
    Itematic Automatic Pick Machine
    Automatic Item Dispenser or Robo Pick Concept
    "A" Frame or Automatic Pick Machine
    Picked Sku Transfer
    Automatic Pick Machine Order Pick Check Activity
    Order Carton/Tote Make-Up and Introduction to a Pick Line or Pick Aisle Station
    Handling Picked Skus
    What Carton Type
    Manual Carton Make-Up Activity
    Mechanical Carton Make-Up Activity
    Carton Make-Up at a Pack Station
    Customer Discreet Label Attachment onto a Customer
    Order/Shipping Carton
    Customer Order Pack Slip Insert
    Small-Item/Flatwear Picked Sku Transport Concepts
    Customer Order Travel Past Pick Positions
    Small-Item/Flatwear Batched Picked Sku Sort Activity
    Customer Order Check Activity
    Customer Order Pack Activity
    Carton Make-Up and Introduction to a Pick Line Start Station
    Sales Literature and Special Delivery Label Insert Activity
    Customer Order Pack Slip, Manifest, and Load Activities
    Customer Order Shipping Container Manifest Activity
    Customer Order Shipping Carton Load Activity
    Sku Pick Position Replenishment
    CUSTOMER ORDER RETURNS, VENDOR RE-WORK, AND
    TRASH HANDLING
    Introduction
    Trash Removal and Trash Disposal Activities
    Trash-Handling Concept Design Parameters
    Customer Order (CO) Sku Rework Activities
    Rework Skus
    Index

    Biography

    David E. Mulcahy