Project Spotlight: Pick Modules

Pick Modules are one of American Surplus' specialties, bringing together every aspect of the material handling space including racking, shelving, conveyor, scanning equipment, workbenches, and oftentimes work platforms.

In this article, we will take a brief look at one of our recent pick module installations to showcase the features and benefits of installating a pick module in your facility.

Our Latest Pick Module

Our most recently completed pick module is a three level, carton flow rack supported pick module covering 36,640 sqft of floor space. Internally, the system utilizes a carton flow design to take advantage of First In, First Out Inventory Control Techniques. Featuring dura-flow style polywheel skate beds, each 60" deep and four levels high persection, this carton flow array is optimized for dynamic picking operations.

Pallet drops and side gates (depicted in the drawing) provide floor access points exclusively to the second level. The third level of the pick module is a flat-top configuration secured by OSHA style handrailings. This "dance-floor" style level effectively doubles the usable floor space and provides a spacious platform where a picking and packing operation could be installed at a later time.

What Is A Pick Module Anyway?

A Pick Module is a self-contained, multi-level system that provides a compact, organized, and high-throughput picking and packing center for your facility. The most elaborate pick modules can be made up of six components:

1. Arrays of Storage Racking store conveyable and pickable products before being loaded into the pick module's picking area by an operator.
2. A Dedicated Picking Area stores SKUs nearby each picker's station to pull from while fulfilling their assigned order sheet. Bringing SKUs directly to the pickers as opposed to tracking down product in the racks ensures faster order fulfillment and reduces errors caused by rushing and fatigue.
3. A Powered Conveyor Race Loop provides a waiting area for completed orders until they're selected by the Packing Team for completion.
4. A Packing Area near the race loop consists of stations where orders are reviewed for accuracy, subsequently packed, and sent to the shipping area for sortation and pickup.
5. A Recirculation Line is accessible from the packing area. Orders that have been identified by the packing team as incorrectly packed are sent down this powered conveyor line back to the picking area to be corrected by the picking team.
6. In The Shipping Area, products are sorted by carrier and sent down the appropriate power conveyor line based on carrier. Powered by an automated barcode scanning system, sortation requires minimal if any human intervention.

By choosing a pick module storage system for your facility, you unlock many key benefits compared to a traditional picking operation:

1. Enforced Error Correction reduces reworks and returns, reducing workload, increasing productivity, and improving margins.
2. Reduced Individual Workload breaks up the picking and packing operation into discrete tasks with unique needs, challenges, and solutions. Streamlined tasks reduce employee error and generate more successful outcomes, satisfied customers, and repeat orders.
3. Optimized Space Use is the primary goal of installing a pick module. Taking advantage of vertical space, mindful positioning of components and workstations, and utilizing automation to move products when possible opens up more floor space to use for other tasks.