Order-Fulfillment and Across-the-Dock Concepts, Design, and Operations Handbook: 1st Edition (Hardback) book cover

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

1st Edition

By David E. Mulcahy, John Dieltz

CRC Press

744 pages | 75 B/W Illus.

Purchasing Options:$ = USD
Hardback: 9781574440447
pub: 2003-12-29
SAVE ~$27.75
$185.00
$157.25
x
eBook (VitalSource) : 9780429242335
pub: 2003-12-29
from $28.98


FREE Standard Shipping!

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

Subject Categories

BISAC Subject Codes/Headings:
BUS058000
BUSINESS & ECONOMICS / Sales & Selling
BUS076000
BUSINESS & ECONOMICS / Purchasing & Buying