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Paperless Picking System (Directed Picking) - as used for Order Fulfillment Here we present a sample application of a "Pick-to-Light" Paperless Picking System, as used for directed picking of product for Order Fulfillment.
Order Picking System – for Order Fulfillment Benefits of GBI's Paperless Order Picking System when used for Order Fulfillment
Pick-to-Light Display Module
Each Pick-to-Light display module contains a two digit LED display, a tri-color indicator light, and three push buttons - one for count up, one for count down and one for pick/put complete. As shown above, the display unit consists of a high impact, molded polycarbonate bezel, which snaps onto the wire-way channel. A laminated, tactile push button pad with the three buttons is permanently bonded to a recess in the bezel. A cutout in the bezel matches a clear window in the tactile module for the two-digit LED display. The LED and color indicator light is attached to the controller printed circuit board, which in turn is attached to the bezel. In the event of a display malfunction, the entire bezel assembly is quickly unsnapped from the channel and replaced. Functional Description of Paperless Picking System - for Order Fulfillment Files are uploaded from the host to the GBI PPS (Paperless Picking System) Server delineating the pick or put requirements for each order and the location of each sku or order within the shelf unit. As the order is scanned at each zone the database is referenced and a light is illuminated at the sku location required for the order. At the same time that the sku location is identified a quantity is illuminated on the Pick Module indicating the required amount for that sku. Where multiple bays are employed, a zone or bay beacon simultaneously lights up indicating that there are requirements for sku's within the zone. Product is then taken from the product carton and placed with the order in the appropriate quantities as indicated by the pick module display. After each operator removes the product from the pick location he/she depresses a button on the pick module indicating that the requirement for that sku and order has been filled. When the last item within the zone has been pulled, the beacon light for that zone is automatically extinguished. This is an indication to the operator to pass the order onto the next zone and scan the next incoming order tote. Increment and decrement buttons are located on each pick-to-light module to allow the operator to adjust the quantity displayed to match the actual amount being supplied (in the event of a shortage). The system fully tracks the "pick" in real time as the order is assembled. The lights and quantity display speed up the picking process and increase picking accuracy by indicating where the product is located and how much is needed without having to reference any paperwork. Additional functions are available to notify floor personnel if a shortage occurs during the process. The PPS automatically detects the condition that an amount less than the requirement was recorded by the operator or a low level has been reached, so that various notifications can be implemented. Indicator Light Feature used in Pick-to-Light Module Each Pick-to-Light Module comes with a bright indicator light. This light is capable of lighting red, green, or amber. It may be used in several ways. One use of this feature is to indicate quantities exceeding 99 pieces (a green light would indicate 100 plus the displayed amount). Another use could be to indicate a status change for that SKU (use your imagination). Still another could be to allow more than one operator to operate within the same zone. In the multiple operator scenario, each operator would be assigned a barcode hand scanner or input. Each of these hand scanners is further associated to a color so that when the order license plate is scanned by the "red" associated scanner, the pick requirement within the zone would indicate a quantity with a red light. The green scanner would show the pick requirement with the green light and so on. Should there be a simultaneous requirement for the same sku from both operators, one color would light first and the second would light up immediately after the first was filled. Each unit contains a two digit LED display, a color indicator light, and three push buttons - one for count up, one for count down and one for pick/put complete. As shown above, the display unit consists of a high impact, molded polycarbonate bezel which snaps onto the wire way channel. A laminated, tactile push button module with three buttons (count up, count down and complete) is permanently bonded to a recess in the bezel. A cutout in the bezel matches a clear window in the tactile module for the two digit LED display. The LED and color indicator light is attached to the controller printed circuit board which in turn is attached to the bezel. In the event of a display malfunction, the entire bezel assembly is quickly unsnapped from the channel and replaced.
The lane displays are mounted on individual rolled steel wire channels, approx. 1.5 inch x 1 inch deep x 8 ft long (or as needed for the application), which are mounted to the face of the order bins. The channels are painted, 19 gauge thick steel with a painted snap on steel cover to cover the gaps between the display units. Beacons for Paperless Order Picking System A single, 15 watt, amber colored, incandescent light assembly (beacon) will be mounted to the top front center of the zone to indicate to the operator that the zone has a requirement to be placed. The system then lights the GBI zone beacon to tell the operator that there is product allocated to a bin or bins in that zone, and displays on the module at each bin the quantity of that product required for that bin. The operator places the required quantity into the bin, then presses the Put or Pick-Complete button on the display module. The pick/put-to-light module sends the quantity displayed on the module to the system computer to be recorded, and the system decrements the order requirements by that quantity.
Carton Flow Selection Lines(a typical arrangement) The carton flow selection area may consist of several Pick to Light or Put lines. Each of the lines may consist of several bays. Each bay (or flow rack) may then consist of one or more shelf levels and each shelf level may consist of several lanes. In front of each lane may be placed a Pick Module to direct the pick or put. Each bay or flow rack may also be equipped with a Bay Light to help direct the operator to a bay to perform the pick or put. Pallet Selection Lines(a typical arrangement)
Pallet Selection Lines are for broken case selection directly from pallets. This arrangement depicts each of the bays equipped with a static shelf above the pallets. This is a description of a single application of GBI's Pick-to-Light System. GBI will customize the order picking systems to meet your requirements. See for a complete description of our Pick to Light & Put System. Other types of sorters include: Applications and processes that are greatly improved through automation using GBI's Sortation Systems:
Other related pages: OEM Materials available on request. GBI Data & Sorting Systems • 1143 West Newport Center Drive • Deerfield Beach, FL 33442 USA |
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