Picking Layout and Material Presentation

Why it matters

The picking layout determines in which order material is selected from the source; the presentation layout determines how it is accessible at the point of use. Although the two take place in different locations, they are parts of the same flow. A large container that is easy to pick in the warehouse may require frequent searching and sorting on the line. A kit that is easy to use on the line can also create long preparation at the source. For this reason the study is not narrowed to the walking distance or to a few motions visible in production. That the right part is present in the right quantity, in a suitable orientation and in the required order is evaluated together. The times of two options whose start and end conditions are not equal cannot be compared directly.

In single-part supply, parts are consumed from their own containers. In pre-kit preparation, the parts needed for a certain product or work sequence are brought together in advance. A kit can move the selecting work from the point of use to somewhere else; this does not mean the work disappears entirely. Work that has moved must not be counted as a gain. Product variety, change frequency, part similarity and the stability of the plan affect the suitable choice. Kitting some parts and presenting others in single containers is also a workable option. Instead of forcing every material into the same arrangement, the sections that cause errors and walking load are examined concretely. The decision is tied to the part family and the condition of use.

A picking line describes the selection of a part and quantity for a certain use. The number of lines is not the same as the number of parts. A line can contain many parts; the denominator of the error rate must be set according to which event is being tracked. If errors are tracked by line, a line with a wrong quantity is one erroneous line. Several defects on the same line can be kept as separate events; but they are not added repeatedly to the line rate. Walking distance is also measured with the same scope over a picking task. A short distance accompanied by a wrong pick or unsuitable handling is not counted as a good result. Distance and accuracy are reported together.

Presentation design must protect quality and safe access. Separating similar parts, making the direction of use distinct and keeping the container identity clear can reduce searching. But trusting only a color difference or moving containers to a place that is hard to reach can create new problems. In kit preparation, how a missing part will be noticed and how an unsuitable kit will be set aside are defined. If the product sequence changes, the validity of kits prepared earlier is checked again. A good decision is not choosing the shelf that looks most orderly. Among options that meet the same need, total human work, errors, response to change and ease of use are tested together; the limits of the short trial are also kept explicit. The feedback of the person using the material also takes part in the assessment. Difficulty distinguishing parts or trouble reaching the bottom of a container, which does not appear in the time table, can affect the sustainability of the arrangement. These reports do not replace numerical data; they show which condition should be observed again. The trial record should link the described difficulty to the part and the presentation arrangement concerned, and should not be closed with only a general statement of satisfaction.

Formula