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

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.

ORDER-FULFILLMENT AND ACROSS-THE-DOCK STRATEGIC CONSIDERATIONS IntroductionPiece and Information FlowsEconomic ValueOrder-Fulfillment or Across-the-Dock Operation Serves Your CompanyOrder-Fulfillment or Across-the-Dock Operation ResourcesCompany Order-Fulfillment or Across-the-Dock Operational ObjectivesImportant Order-Fulfillment or Across-the-Dock Trends and IssuesE-Commerce and the InternetOverviewORDER-FULFILLMENT AND ACROSS-THE-DOCK OBJECTIVES AND THEIR IMPACT ON YOUR COMPANY'S PROFIT AND CUSTOMER SERVICEIntroductionOrder-Fulfillment ActivitiesAcross-the-Dock ActivitiesPiece-Handling CharacteristicsOrder-Fulfillment Operation ObjectiveAcross-the-Dock Operation ObjectiveOrder-Fulfillment and Across-the-Dock Operation ActivitiesOn-Schedule and Accurate Performance of an Order-Fulfillment or Across-the-Dock Operation and Customer Delivery Activities Means Profits and Satisfied CustomersHow to Improve Your Order-Fulfillment or Across-the-Dock OperationShort-Interval SchedulingHow to Project Your Order-Fulfillment or Across-the-Dock Operating BudgetWhy Have Capital Investments?How Does Your Employee Productivity Affect Your Company's Income Statement?Reasons for Economic Justification FactorsOrder-Fulfillment and Across-the-Dock Method Implementation and Project ManagementWhen and How to Select and Use a ConsultantWhy Is High Employee Productivity Important?Seven Order-Fulfilment or Across-the-Dock RatiosKeep It SimpleIt Must Be Cost EffectiveResults Must Be TimelyVarious Measurement StandardsEmployee Productivity Is Tied to Your Annual Expense BudgetORDER-FULFILLMENT SYSTEMSIntroductionThe Basics of Split-Case Order PickingPut System BasicsOther Product IssuesStorage or Picking MediumGeneral Pick-Line LayoutTypes of Order-Fulfillment SystemsSummaryGARMENT-ON-HANGER ORDER-FULFILLMENT OPERATIONSIntroductionHanging Garment or GOH ItemBase Operational Data and Pick-Area InformationPeak, Average, and Most Frequent GOH or Customer-Order VolumesFacility Design Information and ConsiderationsSKU Location on the Pick Line or in the Pick AisleGOH SKU Allocation or Profile MethodsPick-Area DesignBuilding ConsiderationsPick-Line or Pick-Aisle DesignList of ActivitiesPick-Line or Pick-Aisle Sequence of ActivitiesGOH Receiving and UnloadingGOH Sort-and-Count ActivityOther GOH Dock-Area Handling ConsiderationsQuality AssuranceHanging-Garment SteamingPlastic Bag BottomsHanging-Garment Bagging ActivityGOH In-House TransportationHorizontal GOH TransportationNonpowered Horizontal TransportationTrolleyless GOH Transport ConceptsVertical GOH TransportationGOH Static-Rail Storage and Pick MethodsHanging Garment Storage and Order-Fulfillment MethodsGOH Order-Picker Routing PatternsStorage and Pick-Area Design ConsiderationsVarious In-House Hanging Garment Transportation MethodsPlanning a Carton or Full-Case Order-Fulfillment OperationIntroductionCarton or Handling UnitBase Operational Data and Pick-Area InformationFacility Design Information and ConsiderationsSKU Location on the Pick Line or in the Pick AislePick-Area DesignPick-Line or Pick-Aisle Design ParametersPurpose of a Carton Order-Fulfillment OperationCarton Order-Fulfillment ActivitiesOrder-Picker Routing PatternsDisadvantages and Advantages of Electric Pallet TrucksOrder InstructionPick-Position IdentificationElectric Tractor or Tugger MethodPowered Forklift-Truck MethodOrder-Picker Trucks or HROSRail GuidanceEnd-Of-Aisle Vehicle Slowdown DevicesCarton High-Rise Order-Picker TrucksOrder-Pick DevicesCarton High-Rise Order-Picker TrucksOrder-Pick DevicesHigh-Rise Truck Routing MethodsHROS ConsiderationsMethods in Which an Employee Walks to Pick Positions and Picked Cartons Are Transported AwayVarious Employee Pick-to-Powered Conveyor MethodsPick TunnelUnderside Deck or NettingDetermining the Carton-Conveyor Travel PathHow to Cross the Carton-Conveyor Travel PathCarton Travel on a Conveyor Travel PathEmpty-Pallet ReturnEmpty-Pallet PositionElevated Employee WalkwayStairsOrder-Picker Routing PatternOrder-Picker Instruction MethodSorting MethodEmployee Rides to Pick Positions and Picked Cartons Are Transported AwayStock-to-Employee Pick MethodsAutomatic Order-Pick MethodsNonconveyable or Very-Large-SKU Order-Pick MethodsCarton or Pallet ReplenishmentTypes of Pick PositionPut-Away and Withdrawal Transaction-Verification and Inventory-Tracking MethodsVarious Replenishment MethodsSKU Allocation to the Pick AreaVarious Replenishment QuantitiesVarious Timing Methods for ReplenishmentPALLET ORDER-FULFILLMENT OPERATIONSIntroductionBase Operational Data and Area InformationFacility Design Information and ConsiderationsSKU Location in the Storage/Pick AreaPallet Storage-Area DesignPallet FlowDrawingsList of ActivitiesPallet Rack-Row and Vehicle-Aisle Design ParametersPallet-Handling Sequence of ActivitiesSchedule and Yard Control of Vendor and Customer Delivery TrucksReceiving and Shipping Dock LocationsTruck Traffic-Flow PatternsDelivery-Truck Holding AreaLanding Gear PadOther Important Truck FeaturesTruck-Yard SecurityTruck Loading and Maneuvering AreasTruck Dimensions for DocksTruck Dock Design FactorsUnloading and Loading MethodsRailcar Unloading and Loading MethodsVarious Railcar Dock DesignsSingle Railcar UnloadingVarious Railcar Dock Board Designs to Bridge The GapBascule BridgeRailcar Dock-Area OptionsPallet Unloading ActivityPallet Receiving ActivityNeed for Sufficient, Clear Finished-Floor Space and AislesHow to Project the Required Number of DocksHow to Determine the Dock-Area SizeFour Important Rack and Facility DimensionsOther Important Clearances or Open SpacesCeiling Clearance for Fire SprinklersOther Factors That Affect Employee ProductivityPhysical Components of a Pallet Storage/Pick MethodIn-House Transportation MethodsSINGLE-ITEM, GOH, CARTON, OR PALLET ACROSS-THE-DOCK OPERATIONSIntroductionAcross-the-Dock DefinitionObjective of an Across-the-Dock OperationWhat Is RequiredWho from Your Company Is InvolvedThe Vendor ResponsibilityPiece or Customer IdentificationAcross-the-Dock Formats and Piece Flow MethodsVarious Across-the-Dock Piece CharacteristicsReceiving and Shipping Dock Areas Are Most ImportantReceiving and Shipping Dock Projections and Other ConsiderationsUnloading MethodPiece ChangeSmall-Item, Flat Wear, or GOH Across-the-Dock OperationHandling GOH or Hanging Garments in an Across-the-Dock OperationMaster-Carton Across-the-Dock Sorting MethodsPallet or Unit-Load Across-the-Dock Methods

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. Filled with illustrations, forms & tables, this handbook helps you develop the skill and knowledge required to design, organize & operate a productive order-fulfillment or across-the-dock operation.