Order-Fulfillment and Across-the-Dock Concepts, Design, and Operations Handbook

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ISBN: 9781574440447 | 1574440446
Cover: Hardcover
Copyright: 12/29/2003

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Order Fulfillment and Across the Dock Concepts, Design, and Operations Handbook provides insights and tips that warehouse and distribution professionals can use to make their order fulfillment or across the dock operation more efficient and cost effective. Each chapter focuses on key aspects and issues of planning and managing, making it easy to find information quickly. The text includes guidelines for development and projection of accurate facility, inventory, SKU, transactions data and design factors. Filled with illustrations, forms, and tables, this handbook helps readers develop the skill and knowledge required to design, organize, and operate an order fulfillment or across the dock operation.

Chapter 1 Order-Fulfillment and Across-the-Dock Strategic Considerations

(6)

Introduction

(1)

Piece and Information Flows

(1)

Economic Value

(1)

Order-Fulfillment or Across-the-Dock Operation Serves Your Company

(1)

Order-Fulfillment or Across-the-Dock Operation Resources

(1)

Company Order-Fulfillment or Across-the-Dock Operational Objectives

(1)

Important Order-Fulfillment or Across-the-Dock Trends and Issues

(1)

E-Commerce and the Internet

(1)

Overview

(2)

Chapter 2 Order-Fulfillment and Across-the-Dock Objectives and Their Impact on Your Company's Profit and Customer Service

(104)

Introduction

(1)

Order-Fulfillment Activities

(1)

Across-the-Dock Activities

(1)

Piece-Handling Characteristics

(1)

Order-Fulfillment Operation Objective

(1)

Across-the-Dock Operation Objective

(1)

Order-Fulfillment and Across-the-Dock Operation Activities

(9)

Yard Control

(1)

Unloading

(1)

Verifying Piece Quality and Quantity

(1)

Receiving

(1)

Piece Identification

(1)

Packaging

(1)

Horizontal or Vertical Transportation

(1)

Storage

(1)

Deposit

(1)

Inventory Control

(1)

IMS Customer-Order Download

(1)

Carton or Shipping Container Makeup

(1)

Customer-Order Pick

(1)

Sorting

(1)

Replenishment

(1)

Packaging

(1)

Package Sealing

(1)

Package Weighing and Manifest

(1)

Loading and Shipping Activities

(1)

Customer Return, Out-of-Season, and Transfer

(1)

Across-the-Dock Operations

(1)

Maintenance, Sanitation, and Security

(1)

On-Schedule and Accurate Performance of an Order-Fulfillment or Across-the-Dock Operation and Customer Delivery Activities Means Profits and Satisfied Customers

(2)

Why Is an Accurate, Efficient, and Cost-Effective Order-Fulfillment or Across-the-Dock Operation Important?

(1)

What Is the Standard for a Good Order-Fulfillment or Across-the-Dock Operation?

(1)

How to Improve Your Order-fulfillment or Across-the-Dock Operation

(15)

Look at the Employee Numbers

(1)

Develop a Standard

(1)

Use Batched Customer Orders and Dual-Cycle Activities

(1)

Reduce Travel Time and Distance

(1)

Improve the SKU Hit Concentration and Hit Density

(1)

Use ABC or Power SKU Allocation

(1)

Use Kit or Family Group SKUs

(1)

Keep It Simple and Clear

(1)

Use Sequential Order Pick Patterns

(1)

Cube the Order Picker Activity or Automatic Pick Requirement

(1)

Smooth or Level the Work Volume

(1)

Use Part-Time Employees

(1)

Apply the Golden Zone or Proper Elevation and Location of the Pick Position

(1)

Change from Paper Pick Document to Self-Adhesive Label, Paperless, or Automatic Pick Method

(1)

Develop a Good Equipment and Facility Layout and Flow Pattern

(1)

Maintain Clear Aisles and Practice Good Housekeeping

(1)

Maintain Good Lighting in the Pick Aisle or Pick Line

(1)

Change Your Employee Work from a Human-Paced Method to a Machine-Paced Method

(1)

Add Material Handling or Piece Transportation Equipment to Your Employee Work

(1)

Use Automatic Identification

(1)

Provide Sufficient Work

(1)

Use the Pick and Pack Method for High Volume of a Few Single Item or Flat Wear Apparel SKUS for Single-Customer Orders

(1)

Ensure On-Time and Accurate Pick Position Replenishment

(1)

Determine Where to Start the Single-Item Order Pickers

(1)

Have an Arithmetic Progression through a Pick Aisle or along the Pick Line

(1)

Pick Position Numbers That End with Even Numbers on the Right and Pick Position Numbers That End with Odd Numbers on the Left

(1)

Increase Your Employee Pride

(1)

Implement a Work Incentive Program

(1)

Controlling Your Order-Fulfillment or Across-the-Dock Operation

(1)

Employee Productivity Must Be Tied to Your Order-Fulfillment and Across-the-Dock Operation

(1)

Short-Interval Scheduling

(2)

SIS for Your Order-Fulfillment or Across-the-Dock Activities

(1)

How SIS Works

(1)

How to Project Your Order-Fulfillment or Across-the-Dock Operating Budget

(6)

Annual Order-Fulfillment or Across-the-Dock Operating Expense Budget Methods

(6)

Why Have Capital Investments?

(1)

What Is the Capital Expenditure Justification?

(1)

How Depreciation Expense Affects Your Company Income Statement and Balance Sheet

(1)

How Does Your Employee Productivity Affect Your Company's Income Statement?

(1)

What Does Good Employee Productivity Mean to Your Company's Income Statement?

(1)

Reasons for Economic Justification Factors

(3)

Economic Justification Process

(1)

Order-Fulfillment or Across-the-Dock Method Alternatives

(1)

What Is the Useful Life?

(1)

What Is the Rate of Return?

(1)

What Are the Inflation Rate and Growth Rate?

(1)

What Are the Economic Factors?

(1)

What Are the Noneconomic Factors?

(1)

Quantify the Economic and Noneconomic Factors

(1)

Order-Fulfillment and Across-the-Dock Method Implementation and Project Management

(43)

Order-Fulfillment or Across-the-Dock Method Project Management Activities

(1)

How to Estimate Costs, Write Functional Specifications, Review Bids, Administer Contracts, and Implement Your Order-Fulfillment or Across-the-Dock Method

(42)

When and How to Select and Use a Consultant

(5)

Where Do You Find Assistance for Your Operation?

(1)

Providing Accurate and On-Time Operational Design Information

(1)

Internal (In-House) Expert

(1)

External or Outside Consultant

(1)

Order-Fulfillment or Across-the-Dock Equipment Vendors

(1)

What Are the Signals That Your Operation Requires a Consultant?

(1)

What Are the Activities That Require an External Consultant?

(1)

What Should Your Consultant Examine?

(1)

Who from Your Company Should Work on Your Project?

(1)

Order-Fulfillment or Across-the-Dock Project Team Organization

(1)

Where Do You Find Consultants?

(1)

Insights for Your Consultant Selection Process

(1)

Projects That Involve Consultants

(1)

What Information Does Your Consultant Require for Your Project?

(1)

Why Is High Employee Productivity Important?

(8)

What Is Employee Productivity?

(1)

What Are the Business Factors That Affect Your Productivity?

(1)

Areas for Employee Productivity Improvement

(2)

Guidelines for a Successful Employee Productivity Program

(4)

Employee Hours Must Be Consistent

102

(1)

Seven Order-Fulfillment or Across-the-Dock Ratios

103

(4)

Order-Fulfillment or Across-the-Dock Employee (Labor) Ratio

103

(1)

Direct-Employee Handling Loss Ratio

104

(1)

Piece or Customer-Order Movement or Operation Ratio

104

(1)

Customer-Order-Fulfillment Cycle Efficiency Ratio

105

(1)

Space-Utilization Efficiency Ratio

105

(1)

Equipment Utilization Ratio

106

(1)

Aisle-Space Potential Ratio

106

(1)

Keep It Simple

107

(1)

It Must Be Cost Effective

107

(1)

Results Must Be Timely

107

(1)

Various Measurement Standards

107

(2)

Agreed-Upon or Budgeted Standard

108

(1)

Industry Standard

108

(1)

Your Company Standard

108

(1)

Time-Study Standard

108

(1)

Regression Analysis

108

(1)

Employee Productivity Is Tied to Your Annual Expense Budget

109

(2)

Chapter 3 Order-Fulfillment Systems

111

(30)

Introduction

111

(1)

The Basics of Split-Case Order Picking

111

(2)

Put System Basics

113

(1)

Other Product Issues

113

(1)

Storage or Picking Medium

113

(5)

Static Shelving

113

(1)

Carton Flow Racks

114

(3)

Pallet Flow Lanes

117

(1)

Picking Modules

117

(1)

General Pick-Line Layout

118

(1)

Types of Order-Fulfillment Systems

118

(21)

Cart Systems

120

(1)

Pick-to-Paper Systems

120

(1)

Radio Frequency Scanner and Voice Systems

121

(2)

A-Frame Systems

123

(3)

Tilt-Tray or Cross-Belt Sorter Systems

126

(3)

Carousel Systems

129

(3)

Carousel Put Systems

132

(1)

Pick-to-Light and Pick-to-Display Systems

132

(5)

Put-to-Display Systems

137

(1)

Complex Picking Systems

138

(1)

Check Weighing

139

(1)

Summary

139

(2)

Chapter 4 Garment-on-Hanger Order-Fulfillment Operations

141

(162)

Introduction

141

(1)

Hanging Garment or GOH Item

142

(1)

Base Operational Data and Pick-Area Information

142

(1)

Peak, Average, and Most Frequent GOH or Customer-Order Volumes

143

(1)

Peak, Average, and Most Frequent GOH Piece or Customer-Order Volumes

143

(1)

Facility Design Information and Considerations

144

(3)

SKU Location on the Pick Line or in the Pick Aisle

147

(1)

GOH SKU Allocation or Profile Methods

148

(1)

Random or Mixed Method

148

(1)

Separation by Length

148

(1)

Separation by Season and GOH Length

149

(1)

Pick-Area Design

149

(1)

Building Considerations

149

(2)

Building Shape

150

(1)

Building Height

151

(1)

Pick-Line or Pick-Aisle Design

151

(3)

GOH Piece and Customer-Order Flow

151

(2)

Drawings

153

(1)

List of Activities

154

(1)

Pick-Line or Pick-Aisle Design Parameters

154

(1)

GOH Pick-Line or Pick-Aisle Sequence of Activities

155

(1)

GOH Receiving and Unloading

156

(4)

GOH Unloading Methods

157

(2)

Flat-Packed Garment to GOH Methods

159

(1)

GOH Sort-and-Count Activity

160

(1)

GOH Cart Method

161

(1)

Nonpowered Trolley Rail Method

161

(1)

Other GOH Dock-Area Handling Considerations

161

(1)

Grouping Three or Five Pieces into One Bundle

162

(1)

Quality Assurance

162

(1)

Hanging-Garment Steaming

162

(1)

Manual Steaming

162

(1)

Automatic Steaming

163

(1)

Plastic Bag Bottoms

163

(1)

Open Plastic Bag Bottom

164

(1)

Secure Plastic Bag Bottom

164

(1)

Hanging-Garment Bagging Activity

164

(1)

Manual Bagging

164

(1)

Automatic Bagging

165

(1)

GOH In-House Transportation

165

(1)

Horizontal GOH Transportation

165

(2)

Objectives

165

(1)

Design Parameters

166

(1)

Nonpowered Horizontal Transportation

167

(50)

Horizontal Transportation Methods

167

(1)

Above-Floor Nonpowered Horizontal Transportation Group

168

(6)

Overhead Nonpowered Horizontal Transportation Group

174

(22)

Powered Horizontal Transportation Group

196

(21)

Trolleyless GOH Transport Concepts

217

(9)

Various Trolleyless GOH Transport Concepts

217

(9)

Vertical GOH Transportation

226

(16)

Vertical Transportation Objectives

226

(1)

Vertical Transportation Design Parameters

227

(1)

Computer Simulation of a GOH Transportation System

228

(1)

Vertical Transportation Design Factors

228

(1)

Various Vertical Transportation Systems

229

(13)

GOH Static-Rail Storage and Pick Methods

242

(12)

Various GOH Storage and Pick Design Parameters and Key Components

242

(1)

GOH Storage and Pick Position Design Considerations

242

(1)

GOH Storage and Pick Rail Capacity

243

(1)

Various Static-Rail Storage and Pick Methods

243

(11)

Hanging Garment Storage and Order-Fulfillment Methods

254

(23)

Employee Travels to the Pick Position

255

(11)

Stock Travels to a Pick-Position Method

266

(11)

GOH Order-Picker Routing Patterns

277

(1)

Overhead Trolley Picking in the Pick Aisle

277

(1)

Storage and Pick-Area Design Considerations

278

(10)

Types of Pick Position

278

(1)

GOH SKU Location in the Pick Aisle

279

(2)

Pick-Aisle Characteristics

281

(1)

Aisle Direction of Flow

281

(7)

Various In-House Hanging Garment Transportation Methods

288

(15)

GOH Cart Method

288

(1)

Nonpowered Overhead Trolley Method

288

(1)

Trolleyless Method

288

(1)

Tote on a Nonpowered or Powered Conveyor

289

(1)

Completed Customer-Order Package Take-Away Method

289

(4)

Customer-Order Check Methods

293

(1)

Packing Instruction and Shipping Label Preparation

294

(1)

Hanging Garment Packing Considerations

295

(8)

Chapter 5 Planning a Carton or Full-Case Order-Fulfillment Operation

303

(132)

Introduction

303

(1)

Carton or Handling Unit

303

(1)

Base Operational Data and Pick-Area Information

303

(3)

Peak, Average, and Most Frequent Carton or Customer-Order Volumes

304

(2)

Facility Design Information and Considerations

306

(1)

Carton Order-Fulfillment Facility Layout Considerations

307

(11)

Layout Philosophies and Principles

308

(10)

SKU Location on the Pick Line or in the Pick Aisle

318

(1)

Pick-Area Design

319

(3)

Pick-Line or Pick-Aisle Design

319

(1)

Carton and Customer-Order Flow

319

(2)

Drawings

321

(1)

Pick-Line or Pick-Aisle Design Parameters

322

(1)

Purpose of a Carton Order-Fulfillment Operation

323

(1)

Carton Order-Fulfillment Activities

323

(36)

Truck Yard Control Activity

324

(1)

Unloading Activity

324

(1)

Receiving and Checking Activities

325

(1)

Identification Activity

325

(1)

Internal Transportation Activity

326

(1)

Deposit in Storage Activity

326

(1)

Picking and Identification Activity

326

(1)

In-House Transportation Activity

326

(1)

Sorting Activity

326

(1)

Storage Withdrawal and Replenishment Activity

326

(1)

Manifesting Activity

327

(1)

Loading and Shipping Activity

327

(1)

Customer-Returns Activity

327

(1)

Order-Pick Activity

327

(3)

Various Order-Pick Methods

330

(10)

Employee and Picked-SKU In-House Transportation Methods

340

(19)

Order-Picker Routing Patterns

359

(5)

No Routing Pattern

359

(1)

Sequential Routing Patterns

359

(5)

Disadvantages and Advantages of Electric Pallet Trucks

364

(1)

Order Instruction

364

(4)

Keep It Simple and Clear

364

(1)

Information on the Order-Pick Instruction

365

(1)

Various Order-Pick Instructions

366

(1)

Paperless Order-Picking Methods

367

(1)

Pick-Position Identification

368

(3)

No Method

369

(1)

Manual Printing on the Carton

369

(1)

Manually Printed Label on the Carton or Pick Position

370

(1)

Preprinted Self-Adhesive Label

370

(1)

Human- and Machine-Readable Cardboard or Paper Label in a Holder

370

(1)

Placard Hung from the Ceiling or Embedded in the Floor

370

(1)

Digital Display on the Pick Position or Structure

371

(1)

Digital Display on the RF Device

371

(1)

Electric Tractor or Tugger Method

371

(3)

Various Tow Tractors or Tuggers

371

(3)

Powered Forklift-Truck Method

374

(1)

Order-Picker Trucks or HROS

374

(1)

Rail Guidance

375

(4)

Aisle Entry Guides

375

(1)

Rail Installation Parameters

375

(2)

Electronic Guidance Group

377

(2)

When to Use Rail or Wire Guidance

379

(1)

End-Of-Aisle Vehicle Slowdown Devices

379

(2)

Vehicle Slowdown Methods

380

(1)

Carton High-Rise Order-Picker Trucks

381

(2)

Order-Picker Truck with a Carton Load-Carrying Surface

382

(1)

Counterbalanced Truck

382

(1)

Straddle Truck

382

(1)

Platform Truck

382

(1)

VNA Truck

382

(1)

Order-Pick Devices

383

(1)

High-Rise Truck Routing Methods

383

(2)

One-Way High-Rise Order-Picker Truck Routing Pattern

384

(1)

Two-Way High-Rise Order-Picker Truck Routing Pattern

384

(1)

HROS Considerations

385

(1)

Methods in Which an Employee Walks to Pick Positions and Picked Cartons Are Transported Away

385

(5)

Batched or Grouped Customer Orders

386

(1)

Batch Control Methods

386

(1)

Batch Release Methods

387

(1)

How to Determine the Carton Quantity per Batch

388

(1)

Pick Faces or Positions

389

(1)

Pallet Orientation

389

(1)

Pallet Height

389

(1)

Various Employee Pick-to-Powered Conveyor Methods

390

(6)

Standard Pallet Rack, Parallel to the Pick Conveyor

390

(1)

Standard Pallet Rack, Perpendicular to the Pick Conveyor

391

(1)

Carton Flow Rack or Decked Pallet Rack

392

(1)

Pallet Flow Rack, Parallel to the Pick Conveyor

393

(2)

Pallet Flow Rack, Perpendicular to the Pick Conveyor

395

(1)

Pick Tunnel

396

(1)

Underside Deck or Netting

396

(1)

Determining the Carton-Conveyor Travel Path

396

(1)

How to Cross the Carton-Conveyor Travel Path

397

(2)

Safety Gate

398

(1)

Stairs and Platform

398

(1)

Stile

398

(1)

Ships Ladder with Slats between Conveyor Rollers

398

(1)

Carton Travel on a Conveyor Travel Path

399

(1)

Skewed Rollers

399

(1)

Sleeve-Wrapped or Taped Rollers

399

(1)

Angled Deflector

399

(1)

Empty-Pallet Return

400

(1)

Order-Picker Removal of the Empty Pallet

400

(1)

Empty-Pallet Guide Path

400

(1)

Powered Mechanical Pallet-Flow Method

401

(1)

Manually Controlled Overhead Powered Mechanical Hoist with a Set of Hooks

401

(1)

Empty-Pallet Position

401

(1)

Elevated Employee Walkway

402

(1)

Solid-Deck Walkway

402

(1)

Open-Deck or Grated-Deck Walkway

402

(1)

Stairs

403

(1)

Order-Picker Routing Pattern

403

(1)

Order-Picker Instruction Method

403

(1)

Sorting Method

403

(9)

Sorting to Temporary Storage and Shipping Area

404

(1)

Direct-Loading Method

405

(1)

Shipping Cartons on Carts or Pallets

405

(1)

Various Sorting Types

405

(1)

Sorting Is the Heart of the Batched Order-Pick Method

406

(6)

Employee Rides to Pick Positions and Picked Cartons Are Transported Away

412

(2)

Pick Car

413

(1)

Decombe Truck

413

(1)

Stock-to-Employee Pick Methods

414

(5)

Carton Carousel

414

(1)

Cart Carousel

415

(1)

S.I. Cartrac

415

(1)

Sort Link

416

(1)

Storage Area or ASKS Front-End

416

(2)

Mini-Load

418

(1)

Automatic Order-Pick Methods

419

(3)

S.I. Ordermatic

419

(2)

Vertique

421

(1)

Nonconveyable or Very-Large-SKU Order-Pick Methods

422

(5)

Various Nonconveyable Carton Pick Methods

422

(1)

Nonconveyable Carton Pick Vehicles

422

(3)

Nonconveyable Picked-Carton Flow

425

(1)

Arrangement of the Pick Positions

426

(1)

Carton or Pallet Replenishment

427

(1)

Types of Pick Position

427

(1)

Fixed Pick Position

427

(1)

Floating Pick Position

428

(1)

Put-Away and Withdrawal Transaction-Verification and Inventory-Tracking Methods

428

(2)

Human Memory

428

(1)

Handwritten Paper Document

428

(1)

Manual File

429

(1)

Bar-Code Scanning

429

(1)

Various Replenishment Methods

430

(1)

Random Replenishment

430

(1)

Slug Replenishment

430

(1)

Sweep Replenishment

430

(1)

WMS Replenishment

431

(1)

SKU Allocation to the Pick Area

431

(1)

No Method

431

(1)

ABC Method

431

(1)

Family Group

432

(1)

Various Replenishment Quantities

432

(1)

Pallet

432

(1)

Replenishment of One Layer of a Pallet

432

(1)

Replenishment of Less Than One Layer of a Pallet

433

(1)

Various Timing Methods for Replenishment

433

(2)

Manual Method

433

(1)

Computer Method

433

(2)

Chapter 6 Pallet Order-Fulfillment Operations

435

(128)

Introduction

435

(1)

Base Operational Data and Area Information

435

(3)

Peak, Average, and Most Frequent Pallet Volumes or Customer-Order Volumes

436

(2)

Facility Design Information and Considerations

438

(2)

SKU Location in the Storage/Pick Area

440

(1)

Pallet Storage-Area Design

440

(1)

Pallet Flow

441

(3)

Horizontal One-Way Flow Pattern

443

(1)

Horizontal Two-Way Flow Pattern

443

(1)

Drawings

444

(1)

Block Drawing

444

(1)

Plan-View Drawing

444

(1)

List of Activities

444

(1)

Pallet Rack-Row and Vehicle-Aisle Design Parameters

445

(1)

Pallet-Handling Sequence Of Activities

446

(1)

Schedule and Yard Control of Vendor and Customer Delivery Trucks

446

(1)

Receiving and Shipping Dock Locations

447

(3)

Combination Docks

447

(1)

Separated Docks

448

(1)

Scattered Docks

448

(1)

Truck Access to the Docks

449

(1)

Truck Traffic-Flow Patterns

450

(1)

One-Way Pattern

450

(1)

Two-Way Pattern

450

(1)

Delivery-Truck Holding Area

450

(1)

Block Method

450

(1)

45°-Angle Method

451

(1)

Back-To-Back and Side-To-Side Method

451

(1)

Landing Gear Pad

451

(1)

Other Important Truck Features

451

(1)

Truck-Yard Security

451

(1)

Truck Loading and Maneuvering Areas

452

(1)

Truck Dimensions for Docks

453

(1)

Truck Dock Design Factors

453

(13)

Flush-Dock Designs

454

(1)

Open-Dock Design

455

(1)

Enclosed-Dock Design

455

(1)

Side-Loading or Finger Docks

456

(1)

Drive through the Facility

456

(1)

Staggered or Saw-Tooth Dock

456

(1)

Pier Dock

457

(1)

Freestanding Dock or Dock House

457

(1)

Mobile Yard Ramp

457

(1)

Other Dock Design Features

457

(9)

Unloading and Loading Methods

466

(6)

Manual Unloading and Loading Methods

466

(3)

Mechanical Unloading and Loading Methods

469

(2)

Automatic Unloading and Loading Methods

471

(1)

Railcar Unloading and Loading Methods

472

(1)

Various Railcar Dock Designs

473

(1)

Flush Dock

473

(1)

Rail Platform Dock

473

(1)

Inside Rail Dock

474

(1)

Mobile or Remote Dock Ramp

474

(1)

Single Railcar Unloading

474

(1)

Controlled or Selective Railcar Unloading

475

(1)

Double Railcar Unloading

475

(1)

Various Railcar Dock Board Designs to Bridge The Gap

475

(1)

Portable Dock Board

475

(1)

Vertically Stored Dock Board

475

(1)

Portable Railcar to Railcar Dock Board

476

(1)

Bascule Bridge

476

(1)

Railcar Dock-Area Options

476

(1)

Pallet Unloading Activity

476

(3)

Floor-Stacked Method

477

(1)

Pallet-Board Method

477

(1)

Slip-Sheet Method

477

(1)

Container Method

478

(1)

Pallet Receiving Activity

479

(1)

Need for Sufficient, Clear Finished-Floor Space and Aisles

479

(1)

How to Project the Required Number of Docks

480

(1)

Manual Calculation

480

(1)

Manual Simulation

480

(1)

Computer Simulation

480

(1)

How to Determine the Dock-Area Size

481

(3)

Mobile Truck Paths

481

(1)

Pallet Staging Area

481

(3)

Four Important Rack and Facility Dimensions

484

(2)

Clear Space between Two Building Columns

484

(1)

Clear Space between the Finished-Floor Surface and the Lowest Ceiling Obstruction

485

(1)

Pallet Load Dimensions

485

(1)

Pallet Load Bottom Support Device

486

(1)

Other Important Clearances or Open Spaces

486

(1)

Ceiling Clearance for Fire Sprinklers

486

(3)

Clearance between Two Pallets and Rack Support Members

487

(1)

Clearances for a Straddle Forklift Truck

487

(1)

A Rack-Supported Building Means a Wider Rack Base Plate

487

(1)

Flue or Open Space between Back-to-Back Racks or Walls

488

(1)

Finished-Floor Stacked Pallet Clearance

488

(1)

With a Tall-Rack Facility, Allow for Baffle Levels and Additional Sprinkers

488

(1)

White Space along the Wall for a Food Facility

488

(1)

Conveyors Adjacent to a Building Column Require Open Space

488

(1)

Other Factors That Affect Employee Productivity

489

(1)

Physical Components of a Pallet Storage/Pick Method

489

(60)

Pallet Load

489

(14)

Pallet Load-Handling Vehicle

503

(20)

Pallet Load Storage/Pick Position Methods

523

(17)

Pallet Identification

540

(9)

In-House Transportation Methods

549

(14)

Human-Powered Pallet Truck

549

(1)

Powered Pallet Truck

549

(1)

Forklift Truck

549

(1)

Powered Vehicle with a Train of Carts

549

(1)

AGV

550

(13)

Chapter 7 Single-Item, GOH, Carton, or Pallet Across-the-Dock Operations

563

(128)

Introduction

563

(2)

Across-the-Dock Definition

565

(1)

Objective of an Across-the-Dock Operation

565

(1)

What Is Required

566

(1)

Who from Your Company Is Involved

566

(1)

The Vendor Responsibility

567

(1)

Piece or Customer Identification

567

(4)

Human-Readable Identification

568

(1)

Machine-Readable Identification

569

(1)

Human- and Machine-Readable Identification

569

(2)

Across-the-Dock Formats and Piece Flow Methods

571

(3)

Manufacturing Cross-Docking Method

572

(1)

Distribution Cross-Docking Method

573

(1)

Terminal Cross-Docking Method

573

(1)

Various Across-the-Dock Piece Characteristics

574

(1)

Unsorted and Unlabeled Pieces

574

(1)

Unsorted and Labeled Pieces

574

(1)

Sorted and Labeled Pieces

575

(1)

Receiving and Shipping Dock Areas Are Most Important

575

(2)

Receiving and Shipping Dock Projections and Other Considerations

577

(28)

Required Truck Dock Number

577

(4)

Required Number of Shipping or Customer Delivery-Truck Docks

581

(1)

Receiving and Shipping Dock Staging Area or Conveyor Network

581

(1)

Delivery Truck Access to the Truck Docks

581

(2)

Truck-Yard Traffic-Flow Patterns

583

(1)

Delivery-Truck Temporary Holding Area

583

(1)

Landing-Gear Pad

584

(1)

Truck-Yard Security

585

(1)

Delivery-Truck Canopy

585

(1)

Delivery-Truck Unloading and Maneuvering Area

585

(1)

Delivery-Truck Dimensions for the Docks

586

(1)

Other Important Delivery-Truck Yard Features

587

(1)

Delivery Truck Dock Design Factors

587

(18)

Unloading Method

605

(22)

Manual-Unloading Methods

605

(2)

Mechanical-Unloading Methods

607

(20)

Piece Change

627

(1)

Small-Item Across-the-Dock Operation Customer-Order and Shipping Piece

627

(1)

Small-Item, Flat Wear, or GOH Across-the-Dock Operation

628

(13)

Master-Carton Open Activity

628

(1)

SKU Ticketing

628

(2)

Various Small-Item, Flat Wear, and GOH Across-the-Dock Sorting Methods

630

(1)

Across-the-Dock Small-Item or Flat Wear Apparel or Customer-Order Sorting

630

(8)

Packing Verification

638

(1)

Filling the Customer Shipping Container Voids

639

(1)

Seal the Customer Shipping Container

639

(1)

Shipping Address on the Customer Shipping Container

639

(1)

Manifesting and Loading Customer Shipping Containers

640

(1)

Handling GOH or Hanging Garments in an Across-the-Dock Operation

641

(6)

Unloading of GOH

642

(1)

Handling Hanging Garments in Boxes

642

(1)

Unloading Objective

642

(1)

GOH Sorting

643

(4)

Master-Carton Across-the-Dock Sorting Methods

647

(34)

Carton Conveyor Transportation and Sorting Is the Heart of the Batched Across-the-Dock Method

648

(1)

Across-the-Dock Carton Sorting Design Parameters and Factors

648

(1)

Manual Across-the-Dock Carton Sorting Methods

649

(2)

Mechanized Carton Sorting

651

(3)

Various Sorting Surfaces or Conveyor Travel Paths

654

(2)

Mechanical Divert Component

656

(1)

Various Divert Devices or Methods

656

(14)

Carton Conveyor Customer Shipping-Lane Design

670

(1)

Conveyor Considerations

670

(3)

Temporary Hold Area of Across-the-Dock Sorted Cartons Method

673

(1)

Across-the-Dock Shipping Sorting Method

674

(1)

Direct or Fluid Load of Across-the-Dock Cartons

674

(1)

Separating Shipping Cartons into Units

674

(1)

Mimic Display and Control Panel

675

(1)

Nonconveyable Across-the-Dock Carton Sorting

675

(6)

Pallet or Unit-Load Across-the-Dock Methods

681

(10)

Pallet as the Across-the-Dock Unit-Load Support Device

682

(1)

Important Pallet Dimensions

682

(1)

Basic Pallet Designs

683

(1)

Slip-Sheet

683

(2)

Various Pallet Across-the-Dock Transportation Methods

685

(1)

Various Forklift Trucks

685

(6)

Index

691

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Order-Fulfillment and Across-the-Dock Concepts, Design, and Operations Handbook

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Table of Contents

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Order-Fulfillment and Across-the-Dock Concepts, Design, and Operations Handbook

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Table of Contents

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