What are your biggest challenges with high-volume layer picking --labor resources, throughput rates, accuracy, and cost constraints? No matter how you answered that question, pallet flow rack can help! Mallard has gravity flow products for layer picking and mixed-SKU pallet building that minimize labor costs while improving pick speed and productivity. Choose semi-automated or fully-automated solutions to best pair with your operational goals.

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The most simple yet slow and labor-intensive way to build a mixed-SKU pallet is by hand. Workers manually search, pick, and place individual cartons one by one until the palletized order is complete. For a high-volume operation, manual layer picking will likely cost more than reconfiguring for a semi- or fully-automated application.

Drawbacks of Manual Mixed-SKU Pallet Building:
*High labor cost
*Slower productivity
*Lower volume
*Higher potential for mispicks
*High risk for worker injuries

Among the challenges of manual mixed-SKU pallet building is restocking reserve inventory. This can cause wait times or increase safety concerns with forklifts entering labor-heavy workspaces.

Switching to the Ergo Build solution can eliminate not just some of those challenges… but ALL of them!

The Ergo Build Solution for Layer Pick Forklift Attachments
The foundation of the Ergo Build Solution derives from the specially equipped pallet flow lanes that enhance your layer-picking activities. It has been proven to create up to an 11-to-1 Labor Savings, –including the associated costs related to injuries and downtime. With Ergo Build, you can reallocate your team to value-added projects and meet… or potentially exceed customer expectations for order fulfillment rates and customization.

Benefits of Ergo Build for Mixed-SKU Pallet Building
*Significantly boost productivity
*Maintain continuous workflow
*Automatically replenish pick-face pallets
*Remotely control completed pallet release
*Safely extract completed (rainbow) pallets
*Configuring Your Ergo Build Solution

The Ergo Build solution relies on inbound pallet flow lanes to provide the reserve picking inventory and outbound pallet flow lanes where the layer picker builds the mixed-SKU pallets and then releases the completed rainbow pallets for pickup. Here is an overview of the process:

1. Inbound and outbound pallet flow lanes flank the layer pick aisle. The number of each depends on your SKU mix and throughput rates.
2. Inbound lanes are organized by SKU and equipped with the layer pick separator. They continuously and automatically feed inventory to the pick aisle from reserve stock already in the lane.
3. Outbound lanes are the pallet building lanes. The operator places an empty pallet at the aisle position to build the rainbow pallet. The Ergo Build separator holds that pallet in place until the driver releases it via remote control. Once released, it flows away from the pick aisle to the takeaway zone.
4. With separate aisles for loading inventory and completed pallet removal, your layer pick operator is free to work continuously and safely.

Ergo Build Solutions are custom-configured to your space and inventory requirements. Comparisons have shown a 4-to-1 cost savings vs. powered conveyor options. However, if your volume dictates that you take it up a notch… Ergo Build is still there for you!

Pallet Flow Rack for Robotic Arm Mixed-SKU Pallet Building
For high-volume mixing centers, considering a fully automated solution for mixed-SKU pallet building --Ergo Build and pallet flow rack will optimize your application with streamlined and efficient processing.

Similar to the semi-automated Ergo Build solution, your pallet flow lanes will flank your pick aisle. Inbound and outbound flow lanes perform similarly to flow inventory to the picker and the completed mixed-SKU pallets away from the pick aisle for takeaway. The only thing that effectively changes in the layout is the picking mechanism… robotic pick arm vs. forklift layer pick attachment.

No matter your application, gravity flow solutions take your layer picking and mixed-SKU pallet building needs to the next level. The Ergo Build solution is ideal for high-volume applications and mixing center designs. Our solution is fully customized to your space, inventory, and throughput needs. It is easy to operate and cost-effective vs. other alternatives.

Contact Mallard's gravity flow experts for a free consultation and creative solutions to your warehousing and distribution challenges.

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