Easy picking with horizontal carousels

Published on: July 24, 2014 / Updated on: April 24, 2021 – Author: Konrad Wolfenstein

[In collaboration with Kardex Remstar – ADVERTISEMENT]

Picking station with attached horizontal carousel storage

Increased order picking performance through the use of horizontal carousel storage systems

Frequently changing market trends and the constantly intensifying competitive situation present companies with the challenge of continuously optimizing their internal processes in order to reduce costs, increase productivity and increase flexibility in order to survive in the competitive struggle.

Possible starting points in internal warehouse logistics include:

• The efficient storage, provision, and distribution of goods. This is becoming a critical success factor for more and more companies and can be achieved through:
  • increasing the level of automation through modernization of the plants
  • optimal staff utilization
  • the optimization of available storage space and capacity
• necessitate greater storage space requirements, or the optimization of internal storage systems
• Reducing inventory turnover time to achieve cost reductions through time savings

All these points aim to increase the company's order picking performance. Efficient order picking depends crucially on the processing time per order item, and it is essential to keep this time as short as possible. When comparing static and automated storage systems with regard to their picking times per order, travel time (the time the warehouse worker needs to transport the items to the picking station) offers significant potential for savings. With static storage systems, travel time is the key factor, as the picker typically has to cover long distances through the warehouse to reach the respective storage locations. With automated storage systems, such as horizontal carousels, the "goods-to-person" principle – i.e., delivering the items to the employee – minimizes walking distances and thus significantly reduces overall order picking time.

The front-facing access opening of a horizontal carousel allows order pickers quick access to stored goods while requiring minimal floor space. Compared to conventional shelving systems, this significantly reduces walking distances. According to intralogistics provider Kardex Remstar, this can reduce travel time from approximately 65% ​​to approximately 10%. Another advantage: all horizontal carousels belonging to a picking station operate simultaneously, ensuring a continuous flow of goods and minimizing unproductive waiting times for warehouse staff.

The time savings mean that more orders can be processed in the same amount of time, ultimately leading to a significant increase in order picking performance.

A combination of software and hardware: It's the combination that makes it work!

Because what good is the best hardware if there is a lack of an intelligent software solution?

For this reason, intralogistics manufacturers are striving to offer their customers a complete package that combines the advantages of their dynamic storage systems with their proprietary software to achieve synergy effects. Kardex Remstar is leading the way with its "Fast Parts Delivery ," which connects its automated storage and retrieval systems with the Power Pick Global . The optional Smartpick 6000 program is designed for highly efficient picking performance by the machines, ensuring a smooth process for the customer. Naturally, Smartpick 6000 also supports processes such as batching and multi-stage picking operations.

The program can be controlled via a control unit at the workplace or, more recently, also with the help of mobile apps, which allow the devices to be steered and controlled from any location.

Compared to static storage systems, software-supported horizontal carousel storage systems offer a number of distinct advantages:

• Cost savings:
  • by minimizing storage space due to optimized space requirements
  • Through inventory reduction based on precise order tracking. Slow-moving items can thus be identified and reduced, and old stock can be cleared out
• Shorter travel times: The "goods to person" principle automatically provides the picker with the requested items, resulting in a significant reduction in walking distances and travel times.
• Increased accuracy: Scanners and laser systems increase the picking accuracy of the devices to over 99%.
• Faster access to goods: The software-supported warehouse systems enable faster, more precise and more ergonomic access to the stored goods.
• Flexibility: Horizontal carousels have a modular design, which allows the systems to be adapted to new spatial or process-related conditions at any time.

In summary, the use of the system leads to a reduction in time and costs, while simultaneously increasing flexibility.

Horizontal carousels are ideal for use wherever goods need to be stored and retrieved quickly, reliably, and cost-effectively. This makes the concept particularly suitable for companies in the warehouse logistics sector that need to manage their storage facilities

• have a wide range of products
• have a high throughput of order items
• The goods have previously been stored statically in shelving units
• mainly store small to medium-sized parts

These are requirements that apply primarily to companies in the manufacturing sector, the (e-commerce) trade, and warehouse service providers.

Is it even worth it?

Need an example?

Let's consider a company that maintains an inventory of 5,000 items, totaling approximately 125 cubic meters, in a 500-square-meter warehouse, stored on standardized shelving. This warehouse processes 1,800 orders daily, requiring four order pickers. However, a horizontal storage solution capable of handling these volumes would only require one employee, reducing labor costs by 75%. There is also potential for savings in terms of floor space. The modern racking system eliminates the need for employee walkways, reducing the footprint to approximately 160 square meters for a comparable storage volume. Compared to the conventional 500-square-meter model, this represents a saving of over two-thirds of the required space. Simultaneously, the system's intelligent software control allows for higher shelf occupancy rates and improved picking accuracy. According to Kardex Remstar, the mid-six-figure investment required to purchase the horizontal carousels will pay for itself in less than two years due to savings in salaries and floor space. Furthermore, the fact that the company can access its goods and semi-finished products much faster and more flexibly improves its customer position through the enhanced service level.