Re: Lean Manufacturing and Lean Warehousing Series

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Warehouse Modernization and Layout Planning

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 SECTION8 PICKING ORDER lable of Contents
Page No.

8.1 8.2 8.2.1 8.2.2 8.3 8.4 8.4.1 8.4.2 8.4.3 8.5 8.6 8.7 8.7.1 8.7.2 8.7.3 8.8

8 . 8r .
8.8.2 8.8.3 8.8.4 g.g.5 8.9

8 . 9r .
8.9.2 8. I

Systen Selection Order Sequencing Batch Picking Zone Picking S y s E e mC o m p a t i b i l i t y Level-By-Level Order Filling Principles . P r o c e ss Documentation Rackables Order Picking Binnables Order Picking Ro1l-Ttrrough Order Picking Applicat ion Pallet Order Picking Binnables Order Picking MachineAssistedOrderPicking .. OrderPickingTrucks .. Radio Controtled Trailer-Train Man-Aboard S/R Machines Mechanized Order Picking Equiprnent Automated Order Picking Equipment . , Storage Equipment Arrangement Multi-Level Shelving Pallet Rack Shelving

8-I 8-1 8-2 8-2 8-3 8-3 8-3 8-5 8-5 8-7 8-7 8-r 3 8-l 3 8-r 3
. . .. .. 8-f6 8-f5 8-f5 8-f6

8-22 8-22 8-22 8-25 8-25 8_25

SYSTEM SELECTION

The nature of the rnaterial in the Navy supply systen dictates that only a few kinds of applications are appropriate. Producte are either in shipper casea on pallets and shelves or loose in bin and tote boxes on shelves. Ttre shipper cases are hand-selected to pallets and the loose items to tote boxes. These techniques also apply to rnaterial which has been returned from the field or the repair restocking centers for to inventory. In all of this shelf type picking, the selection is made rnanually and there is a considerable amount of identification and verification involved in the picking function. Ttrus, the hunan activity at the shelf is significant. If hand-pushed certs are used, the physique of the order picker limite the height of the pick. A seven foot high shelf systen is generally the maximumwtrich can be used with manual order picking. Any increase in height requires rnultipl.e leve1 shelving, special ladder-equipped carts, or high level order picking trucks. 8.2 SEQUENCTNG ORDER

The sequencing of pick orders before sending them to the order pickers is en important element in the overall efficiency of an order picking operation. The form and content of the pick document can contribute significantly to the presence or absence of picking errors. In general, picking errors should always be avoided even at the expense of increased productivity generit since

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it has occurred than it does to ally costs far more to correct an error after place. prevent in the first the the order error Picking documents must tell picker what is wanted and where it is stored. Identification on the rack or must match that on the pick document. shelf The preferred way to increase efprovided to the ficiency and reduce errors is to keep the information order picker at a minimum. Generally, what is needed is a customer's name or code number, storage address, items, product descriptions, and quantities. Picking pieces to be picked and not state the number of individual documents should the unit of receipt or unit of storage. paper work that eliminates and Computer assisted order picking is one solution can correct or compensate for errors in inventory location or quantity by prornethods are availviding a real time response to the order picker. Several pickers to a computer. include displays on the pick able to link order These rack or portable or vehicle mounted CRT/keyboard terminals.

The two primary means of sequencing orders and controlling batch picking and zone picking. 8.2.L Barch Picking

order

picking

are

In general, when a large volume of full case items is shipped to many custombatch picking ers, can provide Ehe best means to achieve order picking rate. of one iten Batch picking consists of an order picker picking all the units needed to satisfy a nultiple of customer orders. The key element in a batch p i c k i n g o p e r a t i o n i s t h e s o r t i n g s y s E e mt h a t s e p a r a t e s a c o n c e n t r a t e d f l o w o f Batch picking systems depend on a central order cases into individual orders. sorting system to separate the batches into individual orders. Batch picking can be accomplished in several ways. One method consists of a picking station. belt conveyor installed below the end of aisle This conveyor is used to carry enpty tote boxes to the order pickers and carries filled boxA large number of tote boxes are required for this type es back to sorting. stations when order picking of system and there must be a number of sorting trucks or man-ride machines are used for order picking. Batch picking can be with box accomplished by carrying several tote boxes on a vehicle each tote parts for a different customer. The required quantity of a particular holding iten is picked to satisfy the total for all customers in that batch. Ihe order picker then moves to the next item.
8.2.2 Zone Picking

Zone picking resembles a ribucket brigade" process in which an individual customer order is passed from one order picker to another. Each order picker is assigned a specific portion of the storage area and picks only those items conZone picking is a sequential operation in which inditained within that area. another by one or vidual items for a specific customer are picked one after several order pickers. size of pick zones can The advantage of a zor.e picking concept is that the increases or decreases. Ttris permits warehouse change as volume or activity and seasonal managementto balance operations to accoomodate peaks or valleys

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zone slze can

be

automatically

Typically ' zone picking is implemented by installing gravity and power conveyor in each pick aisle. The worker places a tote box or containei on the gt.rity conveyor and nanually pushes the box through the pick zone while picting items for an individual customer order. When the order picker has completed picking within a zone, the container or tote box is placed on the power conveyor for transport to the next zone. There, the next order picker begins working on the order. At the last zone in the system, container" ar" sent by polrer conveyor to the shipping area. Zone picking does not require a separate sorting area since orders sequentially and are completed before being sent to shipping. 8.3 SYSTEM COMPATIBILITY are filled

In applying different pieces of equipment to order picking systems, one must examine the relationships between shelving, automation, and the various methods of order selection and stocking. As a general rule of thumb, manual pickitg operations should be used whenever there is a relatively low transaction rate and a modest number of items. There are a number of levels of sophistication which can be applied to order picking. The transaction rate is the prirnary criterion in the mechanization of open stock picking. In general, the options range from shelf picking by hand onto certs to highly automated systems wtrich deliver the product from computer-controlled release mechanisms. Conpatibility between the order picking and replenishment systems must also be considered. In many systems, both pallet handling and order picking equipment cen use the seme aisle. In most cases, the same aisle guidance system (Section ll.2) can be used for both systems. 8.4 8.4. I LEVEL.BY.LEVELoRDERFILLING Principles

One of the basic elements of order picking is the issue of breakdown of unit loads and shipper containers into a lower level of unit for response to customer demand. Figure 8-1 demonstrates the concept of level-by-level package breakdown. In the development of an order picking system, the level of access or quantity break wtrich is cornmon to the oidet chaiacteristics of the system determines the level of package break or unit degradation to wtrich Ehe order system must respond. In a real life situation, it is not unconmon to have a mix of orders wtrich requires rnultipre levels of access. For example, if a package contains a gross of an item, as in the illustration, a customer could order l7-L/2 gross, which would require one unit load of 15 gross plus one carton of one gross plus 6 inner packs of a dozen each. Good order picking practice would require that the full unit load (16 gross) bypass the order picking system and go directly from reserve storage to the shipping dock or other accumulation area; the lTth gross (a single carton) would be picked from a rackables pallet rack pick area; and the 6 dozen would be taken from a binnables pick area or a roll-through picking system. In this situation, the full case picking from pallet racks would be replenished in full pallet units moving from the reserve area, and the open case picking area (tuz.n to page S - S)

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PALLET LOAD

TIER

CARTON SHIPPING INNER PACK

(DOZEN)

UNIT PACK
(UNIT OF ISSUE TO CUSTOMER)

PIECE INDIVIDUAL
( R E O U I R EB Y D

cusToMER)

PACKAG]E ts]R.]EAKDOWN
Fi-gure 8-1

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 would be replenished in full case units picked from the full case pick rack area. Figure 8-2 demonstrates the economics of this approach. The l{arehouse Design Problem in Section 20 illustretes the flow charting procedures used to determine the proper product flow for transaction rete anatysis. 8.4.2 Process order filling concept is the

The basic principle involved in this nulti-stage same as in all materials handling operations: Move the largest next point of eLze.

possible quantity as far as possible towards the use before breaking down or |tdegradingt' the unit

A11 of the picking techniques discussed in this section should be applied in an appropriate relationship with this basic level-by-level order fiiling concept. Order filling should never take place in a bulk storage erea unlese that order filling is on a unit load tevel. t{ithdrawal. of individual packages fron fu11 pallets in floor-stacked storage operations generetes honeyconbiig, excessive travel, and nultiple handling and ehould be avoided at all.tines 8.4.3 Documentation

Frorn an operational point of view, the order eystem muet be designed to deal with both nultiple eource order filling and reeponeive replenishment on a level-by-level basis. To do this, the computer or order clerk would, upon entry of the order into the prepost inventory system, calculate the nunber of pal: Iets, the nunber of separate full cases, and the number of unite from op"o stock. Tttis infornation would be entered on the order document, end the document would be prepared with no lees than three picking copies. One of these rould be used to trigger the rnovementof the full pallet directly to the order accumulation area. In a modern facility thie would be accomplished by radio dispatching a fork lift truck and placement of the pallet on a towline cart for delivery to the shipping area. Ttre saoe procedure would be ueed to move full pallets from reserve storage to the full caee picking area for replenishing that line. In this cese, the move order would be triglered by the computer on the basis of demand or by a aignal from the full caee picking aiea indicating a ehortage of the iten. The second copy of the order set would be dispatched to Ehe full csne picking recks, and these orders would be routed to the order aeeembly area by towline, pallet and fork truck, or conveyor, depending upon the design of the facility. The order filling operation in this area would algo include the rnovenent of futl caee merchandige forward to the open stock ehelves or flow racks. Ttris action would also be triggered by the computer or a picker eignal. The open etock ordere rrould be picked into a tote box or carton and be dispatched by conveyor or vehicle to the packing aree, and from there to the ordlr assenbly point. Ttre third copy would be used in eituations wtlere open etock items are also involved in the picking system. This third copy would be routed to the open stock order picker, n'ho would gather the rnaterial and either pack it or deliver it to a packing station. Fron that point, it would be routed to the order (turn to page B - Z)

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R E S E R V EE L O C K S T O R A G E

IONAL XONEYCOMEINGLOSS

CENERATEDY FIELDPICKING B
4Orc. I . 3 ' C A3ElIOVE
I

zb'

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A D O I TO N A L A I S L E L O S S I GENERATED Y FIELDPICKING B

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r g o . sc a s E @ 7 3 . 7 5 7 C A S E @ r u u ! p a l u E r u o v e r o D o c K B y p a s sp r c x
LINE.

r I E I o P I C K I N Gw I T H H T G I IR I O E R O R P A L L E T ( R E P L A C E M N T E X T R A 2 P A L L E T M O V E S} rrEtD prcxrrc FRoM FLooR LEvEL

l z . s7 c a s r @ p r c K L r N E s y s r E u - p a L L E T T o R A C K u t { t r TO DOCK

lI]R,A\T]E ]ECONOM ]L NCS

PICK LINE VS FIELDPICKING

Figure 8-2

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I{tren the Navy single line order document is used, the above described threeorder paPer system would, in fact, be three groups of single line entry Part orders destined for the same shipment. Their consolidation into a single picking document or their accuuulation into a packet of single line order documents would be optional procedures wtrich wouLd not significantly affect the nature of the filling operation. A procedure such as that described above will not affect the calculation of T/I ratios if the procedure outlined in Section 14 is followed. The individual areas of pallet, full case, and shelf box order picking will be considered as separate operations with individual T/I ratios. Regardless of its size, any order that involves pallet, full cese, and shelf picks will produce a transaction in each of those systems. In the T/I calculation, the objective is to neasure the activity of each system. 8.5 RACKABLES ORDER PICKING

Figure 8-3 shows a typical warehouse traiter wtrich is frequently used as an order picking vehicle in operations wtlere fairly large cube products are selected. I.lhen this type of operation is used and volume is high, it is not unconmnon to use a trector trailer system to do order picking. Figure 8-4 shows a tractor trailer system approach wtrich, in this case, uses radio control of the tractor so that the order picker doee not have to get on and off the tractor to rnove it as he travels down the aisle. This technique allows for the picking of a large quantity of merchandise in a single pass through the system. Manned S/R units (tr'igure 8-5) and order picking trucks (Figure- g-6) t"r, be used for full caee order picking. The full case order picking procedure used in this Publication is outlined in Section 15. The typical system will be structured around a pallet storage operation with a portion of the pallet positions allocated to full case order picking. To accomplish replenishment, the service aisle must be able to accomnodateboth the pallet system vehicle (Section 2l ) and the order picking (Section 22). As outlined in Section 8.4, the usual form of loaa aegvehicle radation will be frorn pallet to full case. Standard times for theee opeiations can be found in Sections 18 end 22. 8.5 BINNABI"ES ORDER PICKING

Figure 8-7 shows a typical pick cart for binnables order picking with shelving higher than seven feet. With this type of ladder cart, an 8 or 9 foot shelf height is quite feasible, thus increasing cube utilization with a manual picking system. Manned S/R machines (Figure 8-5) can also be used for binnables order picking under either manual or computer control. The most conmon type of high volume order picking vehicle is the order picking rruck (figure 3-6). Ttris unit is adaptable to pallet rack for rackables order pi"ting and to high rise shelving systems for binnables order picking.

(ann to page I - LA)

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wA''R lEltilolustE1HRA,'n[.ER,

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MIC]T CON T']R,OIL]L]ED ]E Xt.]E CRD]ER. ]P]ICKNNGSYSII]ENI

(MtNtMtzED ALKTNG) W
\ Figure 8-4

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%
2_
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A----. - \ . \.

\. .- - - .\ - -

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. NIANN]ED ORDER PICK]E SC]Til]ENIAT'NC

(SHOWING ORDER PICKING NTO PALLET) O Figure 8-5

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PICKtrR TIIUCK OR.]D.trTt

Figure 8-6 8 - 1 1

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T'YP]iCAL LADD]ER, CAR.T

Flgure 8-7

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8.7 ROLL.THROUGH ORDER PICKING

8.7.1

Application

In nany instances where there is high volume picking of a few or even many itens, the concept of flow-through racks or live pallet racks can be considerfor an iten or ed. Whenlarge quantities or high throughput races exist and reduction in storage aisles can more items, the gain in cube utilization than justify the cost of a flow-through system. that, A general rule governing the application of flow-through Bystems states if the unit of handling is degraded from its input level to a lower level of detail as it passes through the flow-through system, application of the flowIf the setection end withthrough system will generally increase efficiency. racks flow-through draws goods in the same units in which they ere entered, not produce any significant advantages. A notable exception to will usually the of the load linits this rule occurs when the crushability or stackability use of bulk storage. 8.7.2 Pallet Order Picking

two aisles, In a flow-through system, each pallet or pick face front requires If the goods are hanthe goods and one to take the goods out. one to input to that dled in and out in the same unit, the handling operation is identical The transwhich would be applied if it were loaded from the pick aisle face. no usually action rates at both ends of the system are identical and there is basic advantage to the flow-through system except for the fact that the input movement is assured. first-out does not interfere with the output and firet-in is degraded or broken down into emaller Conversely, when the product unit with units on the output side, the input handling operation does not interfere or picking operation. Ttris is becauge the input to a flow-through the output system is usually in unit loads or shipper caaes and is therefore at a higher productivity In many instances the input aisle woutd raEe than the output. euffifrom the output aisle in order to permit have a different configuration cient capacity to be built into the system. Figure 8-8 shorrs what is known as a car aisle In this operation. case, a three or more pallets enters the systen in a high voluue input flow stack of The advantage and unit pallets are removed from the system on a demand basis. of this type of operation in bulk storage is the elinination of aisles and the application of movement through the storage system. It also guarantee{t firetfirst-out storage. in In this case the fork truck drives between the roller The storage. raile and pushes the load forward as it placee merchandise in operation can elso be powered. package eelection from Figure 8-9 ehows a nulti-level live roller rack for pallets. ie obvious that the fixed equipnent generates a In this ceae it However, great deal of honeycombing and is a very expensive form of racking. in operations rrhere there is high vetocity movement and selection degrades the deunit load to individual cartons or packages at the output end, it is often sirable to use this type of system. (Ux.n to page I - 16)

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LOAD IN PALLET UANTTIES I

*^:x)y
]F']LCW CR C.N]R. ANSN-]E S1IORAGE
Figure 8-8

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FIXED

gll]f

oF sLor

F ttET LOADS ORK

L I FT I M P U T F R O M SERVICE ISLE A FIXEO EOUIPMENT HONEYCOME P OCCU ANCY

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VARIABLE LOAD LE NG TH

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FOR UNIT PICKING Figure 8-9 8 - 1 5

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Figure 8-I0 shows a typical roll-through operation. This kind of system is quite common in drug order picking, small parts picking, etc. In this situation, the reduced picker travel across the pick face, itr" high item access pattern, the use of zone pick areas, and the technique of picking to a nonpowered conveyor tend to ninimize the cost impact of the labor and "prce disadvantages of the second combined aiste replenishment accivity. The same type of operation can be perforrned with carts, using a packing function on the o,tlreserve stock above the racks. Put side and palletized Ttre disadvantages of this type of picking operation are sinilar to those discussed before i; the ro1l-through pallet racks. Ttris system generates expensive honeycombing and rigidity in the system and requires multiple aisles and a great aeaf of capital investment. Ttre advantage is found in the reduction in picker travel distence along the pick face. Figure 8-ll shows an application configuration for some of the previously mentioned equipment. The upper view shows the relationship between the turret truck and an order picking vehicle in a narrow aisle picking operation cases from pallets in a fully racked situation. Ttre bottorn view shows the same aisle characteristics relating the case pick and pallet load reserve to the replenishment function in a roll-through pick situation. This particular installation configuration is typical of a drug or health and beauty aid type operation. However, it can be applied to eny high volurne small perts sitiation using cartone or tote boxes inbound to a high transaction rate, high item count, piece picking operation. The systern inhibitions and economic risks are as described above. 8.8 8.8.1 MACHINE ASSISTEDORDER PICKING Order Picking Trucks

Towline carts are often used on the forks of order picking trucks to eliminate rnultiple handling of goods between the selection operati6n and vehicle loading or packing activities. To do this, the towline cart is equipped with fori booEs, ls shown-in Figure 8-12 to ensure safe handling at high levels. Figure 8-13 shows a typical order picker/towline cart combination. Figure 8-14 illustretes a typical device used to stack nultiple toce boxes the forks of an order picking truck, thus permitting batch pick operations be performed using an order picking truck and tote boxes. 8.8.2 Radio Controlled Trailer-Train on to

Trailer-train system is sinilar to that shordn in Figure 8-4 is an effective and efficient means of performing rackables order picking. Ttre vehicle is controlled by an operator carrying a radio remote control unii wtrictr can provide a variety of control functions depending on the sophistication of controls. One typical system configuration consists of wire guided a trailer-train system in which the operator radio controls the starting and sEoPPing of the train with the wire guide system used to control the train path. This system permits the order picker to walk beside or near the front or rear of the train and continue to pick merchandise wtrile having the train automatically advance to the next location. (ktz,n to page S - 22)

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N
]LN\T]ESTORA,G]E PNCK]ING SYSIT]EM
( T O C O N V E Y O R N D / O R P A C K T N G P E R A T T O)N A O ,ro
Figure 8-10 8 - 17

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S I D EL O A D I N G S T O R AE G VEHICLE

PALLET R A CK STORAGE

OROER PICKING VEHICLE

CLEAR

P AL L E T RACK STORAGE

ORDER P I C KI N G VEHICLE

B AC K- U P STORAGOVER E FLOWRACKS
FLOWRACKS PICKING

SIDELOAOING S T O RA G E VEHICLE

CONVEYORS R U E E r S-H

L
OETAIL

ORD]E]R ]PNCK]ING A'.]R.]EA

( N A R R O WA I S L E S T O R G E C A S E P I C K I N G A / )
17 06

Figure 8-11

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T"OWN-INtr CART F-ORKtsOOT'S

Figure 8-12

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-:

," ai

ORDEIt PNCKtr]RTItUCK
(wlTH TOwLNE CART t )

Figure 8-13

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t5"x2l" x 12" ToTE 80x ES

RAIL SUPPORT UNOER OTE 8OX T LIP

TOT'E ]EOX ]P]tCKNNG MOD{J]L]E

Figure 8-14

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in Figure 8-5 nay be used Man-aboard S/R machines similar to that illustrated These rnachines permit maxbinnables order picking. or rackables for either reduce and cen significantly height building of available imumurilization Because the order are a consideration. floor area where space restrictions the items in picker is carried aboard the machine, he has full access to all high speed travel and can perform siThe machines feature aisle. operating a horizontal and vertical movement. Items can be picked Eo either rllt".t"o,ts input/output end of the system, the At the boxes. tote pallet or multiple conveyed by a pallet or tote box used for order picking can be automatically conveyor sysEem, if necessary. 8.8.4 Mechanized Order Picking Equiprnent

characterized by nachines that Mechanized order picking equipment is typically The small iten S/R nachine (Figure 8to the order picker. Ehe part deliver 15 ) is orr" ",r"h device and is very similar to the man-aboard S/R nachine deIn tire small itera S/R machine, Parts are stored in in Section 8.8.3. scribed parts is reErieved by the machine and delivered Eo an end trays and a tray of At this operator station, the order picker selects of aisle operator station. item to complete an order, then places the items the proper quantity of each in a separate order accumulation container and returns the storage tray to the the system. These machines have nany of the space and speed advanEages of generally operaEe with greater product securiman-aboard S/R nachines and can ty since an operator is not perrnitted lilithin the storage system. The second popular type of mechanized order picking method is the carousel maCarousels carry a number of storage baekets suspendedat chine (tr'igure 8-16). the top and bottom by a powered track system. Ttre baskets are moved around under operator or computer control and order picking takes unit the carousel Carousels can place from the basket which is stopped at an operator station. Ttrey are, however, provide high density storage and minimize operator travel. storage greeter although 7 to 10 feet lirnited in height to approximately additional units on mezzenine levels. heights can be obtained by installing and stations ttris tras the disadvantage of increasing the number of operator the use of this type of system must be evaluated on the basis of overall sysexpense tem cost, the number of operator stations required, and the additional Typical installations caused by the added operator stations. or inefficiency oPerator stafor carousel units have multiple carousels supporting a single so that. the operator does not have to wait on one machine to index the tion Automatic vertical conveyor units are also available desired basket position. These systems are relevet carousels. from high order picking to permit stricted to retrieving storage trays or tote boxes from the carousel baskets. 8.8.5 Automated Order Picking Machines

Specialized automated order picking machines have been developed by a number in high volume smal1 parts order application specific of manufacturers for been applied in the pharmaThese systems have typically picking operations. Automated order and personal care products industries. cosmetic, ceutical, picking mechines are optimized for high speed order picking of small packaged items which are consistent in terms of the size and strength of the package.

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MOOULAR HANDLING UNIT

HANOLINGUNIT ANO SHELF BOXES

TYPNCA]L NI]tN]t. S / R NIACHT]IN]E

Figure 8-15

8 - 2 3

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ROIIA,RY CONVEYOR. ts[NS

Figure 8-16

8 - 2 4

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 Typical items picked by such systems include packaged health and beauty aids, packaged automotive parts such as spark plugs, points, etc., pharmaceutical items such as pills and medications, and cosmetics. 8.9 8.9.1 EQUIPMENT STORAGE ARRANGEMENT Multi-Level Shelving

Figure 8-I7 shows a modular multi-level shelving installation wtrich can optiin rnanual picking operations. This type of installation mize cube utilization Figure 8-18 sholrs a modular layout for is in general use in Navy facilities. conventional rnanual merchandise selection using a rurn-pushed order picking inetallaTtris layout can be used in both single level cart. and multiple tions. In this system, the size of the aisle is directly related to the size If zone picking and pass-through documenEation are used, the of the cert. In aisles and the cart can pass from one picker to another. can be onelray this nethod, as each picker finishes the order in his zorLe, he will remove the cart and park it or place it on a towline or a pickup point for a trector trailer train. IIe leaves Ehe paperwork with the cart, and the next picker follows This permits narrolr aisles, since passing is not required, and on. queueing is eliminated unless more than one cart is working within a singte zone. The arrangement in Figure 8-18 is designed around the shelf box operation. In this cese, the shelf depth is 18 inches. It is desirable to allow sufficient aisle epace for carts to pass, thus avoiding the problem of queuing. Generally, the aisle width should be twice the lridth of the cart plus 18 to 24 inches, depending upon the nature of the merchandise, the rapidity the of picking, In any case, and the number of people involved in the operation. passing aisles are essential wtren zone picking and pass-through documentation are not used. Another consideration in the design of aisle widths for a manual picking operation is the nature of the input function. If the goods arrive in the picking area on pallets, it is essential thet the aisle be wide enough to handle e pallet on a pallet jack or other nachine. Since the Navy pallet is 40" x 48", the aisle would then have to be no less than 50 inches wide in order to safely m'neuver in the aisle to put merchandise away with a hand jack, electric pallet jack, or fork lift nachine. Conversely, if the merchandise is placed in storage by hand from a picking cart, the aisle width dimension is dominated by the picking operation. 8.9.2 Pallet Rack Shelving

Iland picking operations involving heavy items often necessitate the uae of pallet rack type structures to support the shelves. Figure 8-19 ehows this type of installation. This type of storage rack consists of standard pallet rack with solid wood, rnetalr or perforated or expanded metal decking. These heavy duty pallet rack shelves can be installed in configurations identical to pallet racks and can be serviced by many of the same vehicles. In rnany instances, these rack shelves are used interchangeably for both palletized and Loose merchandise.

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2" TYPrcAL OF TOP AND BOTTOM

36 (TYP}

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THIRO LEVEL-r

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lTYPNCANMU]LII]I- ]LIEVEN, STilE]LV]ING A]RR ANG]ENfi]ENIT

Figure 8-17

8 - 2 6

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f,o'-o':

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TYPICAL S H L V I N G

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r,F

]LAYO]U]I STIUDY SHtlE[.\TNNG

( SHELFBOX STORAGE CART SERVICE )
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METAL OR GRID OECKING

S T E PD O W N - T Y P E R I STRNGE

UP TO t80" SHELVING TO SUIT REOUIREMENTS

INSTALLED IN

24" OR 49"

D O U E L EU N I T S BACK TO BACK OR SINGLE ROWS A C C E S S E DF R O M BOTH SIDES

3" Si-f.-

70" oR s6"

\-3"

TY]PNC^A.]L R,ACK N.OADED SIIO]R.AG]E ]HIA,.ND

( O E S I G NS I M I L A R T O P A L L E T R A C K )

Figure 8-19 8 - 2 8

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