Experience: Case Studies

State-of-the-art capability studies and demonstrations

Internet Fulfillment System

KLG was chosen by this store and internet retailer of apparel and accessories to implement a three level order picking system. This project was successfully executed on a tight time-frame in order to get the facility running prior to the client's busy season.

Additional Photos:

The system is a "pick & pass" order picking system with the orders starting at the floor level of the three level mezzanine. Orders are started by operators placing the order pick list in an empty tote and releasing the tote into the system. The order tote travels through the three level system stopping at any of the (12) zones that contain a pick for the order. The orders then proceed through check, pack and an optional gift wrap station. A narrow belt sorter diverts the packages into mail tubs for the appropriate carrier.

The system contains over 44,000 locations and allows the client to process over 5,000 picks and 2,200 orders per day. The WCS allows the operators the adjust inventory /shortages on the fly. The paper based picking system is currently being upgraded to RF.

System Features:

  • Intelligrated Conveyor with 24 volt "pick and pass" transfers. TGW dual sided narrow belt sorter with right angle divert. Separate delivery conveyor to each level for put-away items.
  • Empty tote conveyor to transport order totes between pack and order start stations.
  • Three level vertical lift for delivery of pallets and bulky loads to upper levels.