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




ISBN 9781574440447
Published December 29, 2003 by CRC Press
744 Pages 75 B/W Illustrations

 
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Book Description

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 operations more efficient and cost-effective. Each chapter focuses on key aspects of planning and managing, making it easy to find information quickly. The text includes guidelines for development and projection of accurate facility, inventory, SKU, and transaction data, as well as design factors. Filled with illustrations, forms, and tables, this handbook helps you develop the skill and knowledge required to design, organize, and operate a productive order fulfillment or across-the-dock operation.

By applying the recommendations found in this book, you will be able to reduce product damage, enhance product flow, increase employee productivity, improve customer service, reduce operating costs, maintain on-schedule deliveries, and ensure asset protection.

Table of Contents

ORDER-FULFILLMENT AND ACROSS-THE-DOCK STRATEGIC CONSIDERATIONS
Introduction
Piece and Information Flows
Economic Value
Order-Fulfillment or Across-the-Dock Operation Serves Your
Company
Order-Fulfillment or Across-the-Dock Operation Resources
Company Order-Fulfillment or Across-the-Dock Operational
Objectives
Important Order-Fulfillment or Across-the-Dock Trends and
Issues
E-Commerce and the Internet
Overview

ORDER-FULFILLMENT AND ACROSS-THE-DOCK OBJECTIVES AND THEIR IMPACT ON YOUR COMPANY'S PROFIT AND CUSTOMER SERVICE
Introduction
Order-Fulfillment Activities
Across-the-Dock Activities
Piece-Handling Characteristics
Order-Fulfillment Operation Objective
Across-the-Dock Operation Objective
Order-Fulfillment and Across-the-Dock Operation Activities
On-Schedule and Accurate Performance of an
Order-Fulfillment or Across-the-Dock Operation and Customer Delivery Activities Means Profits and Satisfied Customers
How to Improve Your Order-Fulfillment or Across-the-Dock
Operation
Short-Interval Scheduling
How to Project Your Order-Fulfillment or Across-the-Dock
Operating Budget
Why Have Capital Investments?
How Does Your Employee Productivity Affect Your Company's
Income Statement?
Reasons for Economic Justification Factors
Order-Fulfillment and Across-the-Dock Method Implementation
and Project Management
When and How to Select and Use a Consultant
Why Is High Employee Productivity Important?
Seven Order-Fulfilment or Across-the-Dock Ratios
Keep It Simple
It Must Be Cost Effective
Results Must Be Timely
Various Measurement Standards
Employee Productivity Is Tied to Your Annual Expense
Budget

ORDER-FULFILLMENT SYSTEMS
Introduction
The Basics of Split-Case Order Picking
Put System Basics
Other Product Issues
Storage or Picking Medium
General Pick-Line Layout
Types of Order-Fulfillment Systems
Summary

GARMENT-ON-HANGER ORDER-FULFILLMENT OPERATIONS
Introduction
Hanging Garment or GOH Item
Base Operational Data and Pick-Area Information
Peak, Average, and Most Frequent GOH or Customer-Order
Volumes
Facility Design Information and Considerations
SKU Location on the Pick Line or in the Pick Aisle
GOH SKU Allocation or Profile Methods
Pick-Area Design
Building Considerations
Pick-Line or Pick-Aisle Design
List of Activities
Pick-Line or Pick-Aisle Sequence of Activities
GOH Receiving and Unloading
GOH Sort-and-Count Activity
Other GOH Dock-Area Handling Considerations
Quality Assurance
Hanging-Garment Steaming
Plastic Bag Bottoms
Hanging-Garment Bagging Activity
GOH In-House Transportation
Horizontal GOH Transportation
Nonpowered Horizontal Transportation
Trolleyless GOH Transport Concepts
Vertical GOH Transportation
GOH Static-Rail Storage and Pick Methods
Hanging Garment Storage and Order-Fulfillment Methods
GOH Order-Picker Routing Patterns
Storage and Pick-Area Design Considerations
Various In-House Hanging Garment Transportation Methods

Planning a Carton or Full-Case Order-Fulfillment Operation
Introduction
Carton or Handling Unit
Base Operational Data and Pick-Area Information
Facility Design Information and Considerations
SKU Location on the Pick Line or in the Pick Aisle
Pick-Area Design
Pick-Line or Pick-Aisle Design Parameters
Purpose of a Carton Order-Fulfillment Operation
Carton Order-Fulfillment Activities
Order-Picker Routing Patterns
Disadvantages and Advantages of Electric Pallet Trucks
Order Instruction
Pick-Position Identification
Electric Tractor or Tugger Method
Powered Forklift-Truck Method
Order-Picker Trucks or HROS
Rail Guidance
End-Of-Aisle Vehicle Slowdown Devices
Carton High-Rise Order-Picker Trucks
Order-Pick Devices
Carton High-Rise Order-Picker Trucks
Order-Pick Devices
High-Rise Truck Routing Methods
HROS Considerations
Methods in Which an Employee Walks to Pick Positions and
Picked Cartons Are Transported Away
Various Employee Pick-to-Powered Conveyor Methods
Pick Tunnel
Underside Deck or Netting
Determining the Carton-Conveyor Travel Path
How to Cross the Carton-Conveyor Travel Path
Carton Travel on a Conveyor Travel Path
Empty-Pallet Return
Empty-Pallet Position
Elevated Employee Walkway
Stairs
Order-Picker Routing Pattern
Order-Picker Instruction Method
Sorting Method
Employee Rides to Pick Positions and Picked Cartons Are
Transported Away
Stock-to-Employee Pick Methods
Automatic Order-Pick Methods
Nonconveyable or Very-Large-SKU Order-Pick Methods
Carton or Pallet Replenishment
Types of Pick Position
Put-Away and Withdrawal Transaction-Verification and
Inventory-Tracking Methods
Various Replenishment Methods
SKU Allocation to the Pick Area
Various Replenishment Quantities
Various Timing Methods for Replenishment

PALLET ORDER-FULFILLMENT OPERATIONS
Introduction
Base Operational Data and Area Information
Facility Design Information and Considerations
SKU Location in the Storage/Pick Area
Pallet Storage-Area Design
Pallet Flow
Drawings
List of Activities
Pallet Rack-Row and Vehicle-Aisle Design Parameters
Pallet-Handling Sequence of Activities
Schedule and Yard Control of Vendor and Customer Delivery
Trucks
Receiving and Shipping Dock Locations
Truck Traffic-Flow Patterns
Delivery-Truck Holding Area
Landing Gear Pad
Other Important Truck Features
Truck-Yard Security
Truck Loading and Maneuvering Areas
Truck Dimensions for Docks
Truck Dock Design Factors
Unloading and Loading Methods
Railcar Unloading and Loading Methods
Various Railcar Dock Designs
Single Railcar Unloading
Various Railcar Dock Board Designs to Bridge The Gap
Bascule Bridge
Railcar Dock-Area Options
Pallet Unloading Activity
Pallet Receiving Activity
Need for Sufficient, Clear Finished-Floor Space and Aisles
How to Project the Required Number of Docks
How to Determine the Dock-Area Size
Four Important Rack and Facility Dimensions
Other Important Clearances or Open Spaces
Ceiling Clearance for Fire Sprinklers
Other Factors That Affect Employee Productivity
Physical Components of a Pallet Storage/Pick Method
In-House Transportation Methods

SINGLE-ITEM, GOH, CARTON, OR PALLET ACROSS-THE-DOCK OPERATIONS
Introduction
Across-the-Dock Definition
Objective of an Across-the-Dock Operation
What Is Required
Who from Your Company Is Involved
The Vendor Responsibility
Piece or Customer Identification
Across-the-Dock Formats and Piece Flow Methods
Various Across-the-Dock Piece Characteristics
Receiving and Shipping Dock Areas Are Most Important
Receiving and Shipping Dock Projections and Other
Considerations
Unloading Method
Piece Change
Small-Item, Flat Wear, or GOH Across-the-Dock Operation
Handling GOH or Hanging Garments in an Across-the-Dock
Operation
Master-Carton Across-the-Dock Sorting Methods
Pallet or Unit-Load Across-the-Dock Methods

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