Easy picking with horizontal carousels

Published on: July 24, 2014 / Update from: April 24, 2021 - Author: Konrad Wolfenstein

[In collaboration with Kardex Remstar – ADVERTISING]

Picking station with attached horizontal carousel warehouse

Increase in picking performance through the use of horizontal carousel warehouses

Frequently changing market trends and the ever-increasing competitive situation present companies with the task of continually optimizing their internal processes in order to reduce costs, increase productivity and increase flexibility in order to be able to survive the competition.

Possible starting points in internal warehouse logistics include:

• The efficient storage, provision and distribution of goods. For more and more companies, this is one of the critical success factors and can be done through:
  • increasing the level of automation by modernizing the systems
  • optimal utilization of staff
  • optimizing the available storage space and capacities
• Well-thought-out space management, because growing product ranges require greater storage space and the optimization of internal storage systems
• Shortening the inventory turnover time to achieve cost reductions by saving time

All points aim to increase the company's picking performance. Efficient picking depends crucially on the processing time per order item and it is necessary to keep this time period as short as possible. If you compare static and automated storage systems with regard to their picking times per order, the travel time in particular (= the time that the warehouse worker needs to transport the items to the picking point) offers great potential for savings. In static storage systems, the travel time is the essential factor, as the order picker usually has to travel long and frequent distances through the warehouse to get to the respective storage locations. With automated storage systems, such as horizontal carousels, the “goods to person” principle – i.e. the delivery of the items to the employee – can be used to reduce walking distances to a minimum and thus significantly reduce the overall picking time.

The front removal opening of a horizontal carousel allows the order picker to quickly access the stored goods in a minimal footprint. Compared to conventional shelving rack storage, a large part of the walking distance is saved. According to the intralogistics provider Kardex Remstar, the proportion of travel time can be reduced from around 65% to around 10%. Another advantage: All horizontal carousels belonging to a picking station work at the same time, which ensures continuous transport of goods and reduces unproductive waiting times for warehouse staff to a minimum.

By saving time, more orders can be processed in the same time, which ultimately leads to a significant increase in picking performance.

Combination of software and hardware: It's the combination that counts!

After all, what use is the best hardware if there is a lack of an intelligent software solution?

For this reason, intralogistics manufacturers strive to offer their customers a complete package in which the advantages of their dynamic storage systems can be combined with the specially developed software in order to achieve synergy effects. Under the keyword Fast Parts Delivery leading the way with a network solution in which it connects its automatic rack warehouses with the Power Pick Global . The Smartpick 6000 program, which is offered there as an option, is designed to ensure highly efficient picking performance of the machines so that this process runs smoothly for the customer. Of course, Smartpick 6000 also supports processes such as combining order items (batching) and multi-stage picking processes.

The program can be controlled using a control unit at the workplace or, most recently, with the help of mobile apps, with which the devices can be controlled and controlled from any location.

Compared to static storage systems, software-supported horizontal carousel warehouses have a number of clear advantages:

• Cost savings:
  • by minimizing storage space due to optimized space requirements
  • through inventory reduction due to accurate order tracking. In this way, slow sellers can be identified and reduced, and old stocks can be eliminated
• Shorter travel times: Thanks to the “goods to person” principle, the requested items are automatically provided to the picker, which leads to 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 storage systems enable faster, more precise and more ergonomic access to the stored goods
• Flexibility: Horizontal carousels have a modular structure with which the systems can be adapted to new spatial or process-related conditions at any time.

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

The use of a horizontal carousel is ideal wherever it is important to store and provide goods quickly, reliably and cost-effectively. The concept is particularly suitable for warehouse logistics companies in their warehouses

• have a wide range of products
• have a high throughput of order items
• Until now, the goods have been stored statically in shelving units
• store mainly small to medium-heavy parts

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

Is it even worth it?

Would you like an example?

Let's take a company that has a range of 5,000 items with a volume of around 125 cubic meters on a total area of ​​500 square meters, which it stores on standardized shelves. 1,800 calls are made from this warehouse every day, which require 4 order pickers to process. However, a horizontal storage solution that can handle these volumes only requires one employee, reducing labor costs by 75%. There is also potential for savings in terms of the space required, because in the modern rack warehouse the walkways that would otherwise be required for employees can be omitted, which reduces the space requirement to around 160 square meters for a comparable storage volume. Compared to the conventional model with 500 square meters, over two thirds of the space can be saved. At the same time, thanks to the system's intelligent software control, the areas can be filled to a higher degree and the picking accuracy can be refined. According to Kardex Remstar, the mid-six-figure investment required to purchase the horizontal carousel will pay off in less than two years due to the savings in salaries and stand space. The fact that the company can access its goods and preliminary products much more quickly and flexibly also improves its position with customers through the improved service level.