KEIHIN Distribution Co., Ltd.

Logistical analysis-based relay picking system maximizes conveyor use

  • Product Category:General Goods
  • Industry:E-commerce
  • Solution:Deal with Massive Workloads
  • Picking System:Pick to Light

Issue background

  • Keihin Distribution needed to perform picking for a large number of orders (roughly 6,000 per day).
  • The company sought a highly efficient workflow built on the visualization of A products, B products, and C products based on logistical analysis of item hit rates.

Benefits

Picking efficiency and inventory accuracy improved

  1. Productivity improved such that the company can now process roughly 7,000 orders per day (busy period productivity level).
  2. Picking speed increased after two conveyor lines were introduced for high hit-rate items (A product) to enable picking for two orders at a time.
  3. The final conveyor is split into a line for B/C products (low hit-rate items) and an inspection line, and orders that have already been picked are allowed to bypass the B/C line and go straight to the inspection line. This configuration has improved work efficiency.

Solution

Pairing conveyors and pick to light

The final result is a pick to light system linked to free conveyors that comprise two lines with identical flow rack and conveyor layouts for high hit-rate items (A products), and a conveyor with a mid-sized rack for low hit-rate items (B/C products).

Products used in this case