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THE MAZE 
OF WAREHOUSE DESIGN

10 Universal Principles to guide you through...

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Design work to man, not man to work:
Stop the endless searching aisle after aisle. Condense the faster moving stock into
zones with units on flow rack or carousels.

Process orders in groups:
Pick more than one order at a time by any
of several ways: batch picking, zone picking, cluster picking and wave picking.

Zone design the work area:
Allow more than one operator to access
an order at the same time.

Handle an item the fewest times:    
Add value warehouse style at each step.
Make each step part of the total process;
if you stage an item, sort it too.

Move items in the highest quantity of measure: Pick in discrete measures,
ie. by bag, blister pack quantity, eaches

Allow an order to enter or exit the system at will: Let orders skip zones. Plan for hot orders. Use order management software.

Have a plan for restocking:
Restocking accurately is the critical
first step to picking accurately.

Compress tasks:
Combine product movement with intelligence, i.e. tagging, bagging, sorting for the next operator.

Develop and use an item slotting plan:
The benefits of correct product placement cannot be emphasized enough.

Do it once and do it right:
Use data collection devices for accuracy and accountability. Eliminate errors, track
who did what when! Use the results as
a training tool.

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ATI provides consulting on system design and implementation
If you have a specific project in mind or would like further
information, call Bryan Kelly at 641.472.0941

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