CA2017554C - Alternating push back selective rack storage system - Google Patents

Abstract

ALTERNATING PUSH BACK
SELECTIVE RACK STORAGE SYSTEM

Abstract of the Disclosure A flexible rack system for use in distribution centers servicing retail stores with food and non-food items and comprising rows of pallet storage racks of different types within the same row and arranged in a predetermined pattern of high movement, medium movement and low movement racks including both selective and push-back rack types which permit one filling an order to carry out his task with a minimum number of stops and a time for picking selected items being significantly reduced.

Description

201755~

ALTERNATING PUSH BACK
SELECTIVE ~ACK STORAGE SYSTEM
Background of the Invention This invention relates generally to storage systems and more particularly to a method and apparatus for facilitating and expediting the flow of packaged goods from their manufacturers through intermediate storage facilities at regional distribution centers.
A distributlon center 9tores thou8ands of items in inventory and attempts to maintain each item at the optimum minimum inve~ntory level where it will not run out of goods and generally avoid static inventories which tie up money in a non-productive mode. Goods are selected for and shipped to retail outlets according to each outlet' 8 needs.
These needs are based on maintaining flexible but pre-; established inventory levels to insure meeting and satisfying the demand of the consuming public serviced by that retail outlet.
Goods are stored in different areas within the distribution center depending on the nature of the products. There is room temperature storage for canned goods and non-food itemsJ there are refrigerated storage areas for fruits, vegetables, milk and mllk products, meats and meat products, floral and garden products~ special banana rooms for ripening and storing banana frozen storage areas for ice cream products and for frozen foods;
special enclosed areas for sensitive items such as tobacco products, photographic supplies, beauty and health aid items; and isolated storage areas for combustibles and toxic garden sprays.
The distribution center constantly addresses the problems of maintaining minimum but adequate inventories, moving them into and out of storage'quickly and efficiently, at lowest possible labor cost, holding its fleets of material handling equipment to barest but adequate minimums, and is especially concerned with optimum utilization of available storage space. Furthermore, it is 2017554~

important to store the vast array of goods in such a manner that each item is readily accessible.
It is also desirable that the products be stored in such a way that they are removed in inverse order of time of receipt, that is, items received at a given date move into the distribution chain before replacement items received at a subsequent date.
Another important requlrement 18 that items be warehoused wlthin the distrlbutlon center ln a location pattern that permits rapid access with minimum labor for item selection for transfer to an accumulatlon area as a prelude to loading trucks for transport of these items to their respective retail outlets.
Present practice to accompli;sh these objectives includes placing packaged goods on standard sized pallets and then positioning these pallets on racks so that each space in the rack holds one pallet. The height of the racks is limited by the ceiling height of the storage bullding and by the helght that a orklift can lift a pallet. Normally, ceiling height is the limiting factor.
In an attempt to achieve the above stated ob~ectives, a number of known rack type storage sy~tems have been designed each 9eeking improved eficiencies in performance.
SummarY
It is the primary object of the present invention to impeove the flexibility of storage and distribution facilities which will result in savings of storage space, retrieval time, and labor costs permitting better inventory control, an enhanced stock rotation capability, and improved utili~ation of material handling equipment.
It is a further object of the invention to improve the flow and distribution of all types of packaged goods originating from the manufacturer through an intermediate storage center where the packaged goods are broken down into smaller lots to fill orders from retail outlets for sale to their customers.
The inventlon comprlses an lmproved plcklng scheme and 20~17~S9L

a novel system of different types of racks for use in distribution centers servicing retail stores with food and non-food items such as are found in supermarkets. The inventive method and apparatus can also be used in distribution system complexes servicing industries other than retail markets and supermarket chains including but not limited to hardware, bullding supplies, pharmaceutlcals, electrl~al and computer aomponents, naval store~, automotlve supplles, machl~e parts, books and magazines, etc.
Brief Descrlptlon of the Drawing The invention will be better understood when considered in connection with the following drawing Eigures wherein:
Figure 1 is a perspective view of a single-deep back-to-back selective container type storage rack according to the known prior art~
Figure 2 is a qide elevational view of a conventional double-deep, back-to-back pallet type selective storage rack~
Figure 3 is a side elevatlonal vlew of a well known three-deep pallet type storage rack~
Flgure 4 is a side elevational vlew of a slx-deep pallet type flow-through storage rack al50 known ln the prlor art~
Figure 5 is a perspective view of a storage rack system according to one embodiment of the subject invention~
Figure 6 is a plan view illustrative of a picking scheme illustrating the method of the subject invention;
Figure 7 is a perspective view of a storage rack system according to another embodiment of the subject invention: and Figure 8 is a plan view illustrative of a picking scheme further illustrative of the method of the subject invention.

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Detailed Descriptlon of the Invention Prior to considering the details of the present invention, it is desirable to further review and compare the use of known conventional storage rack systems.
Packaged goods are handled, where possible, on standardized pallets generally 4B x 40 inches in size and built for handling by fork lifts or pallet ~ack machlnes.
Stacking pallet loads o product directly one on top the other can result ln damage to the bottom p~llet load.
This possibllity o damage increases as the number and height of the pallets increase. Moreover, there is danger that the pallets will topple as the goods on the bottom pallet become distorted from the weight of the top pallet or pallets. Furthermore, if it is desired to access the bottom pallet in a stack of two or more pallets, it will require removing the top pallets and then restacking them after the bottom pallet is accessed. If only part of the bottom pallet is removed, and a partial layer remains, then restacking would result in an unstable load space and other options would have to be exercised ~uch as starting a new 8 tack.
The answer to thls problem ls to stack pallets in racks where each pallet occupies it5 own rack space and is lnserted or removed from that space without affectlng other pallets in that rack. The height of the racks depends upon ceiling height in the warehouse and the abillty of the forklift to reach every space in the rack. The racks are positioned next to each other to form a row of racks, and the whole distribution center or designated sections of the distribution center is filled with rows of such racks. The rows are spaced to permit forklifts to move between the rows with enough room to access each rack for placing or removing pallets from any rack space in the rows. In addition, room is provided at least at one end of each row in order to permit forklift travel from one row to any other row in the area. It is also usually desirable to have a turning space at both ends of each ! OW, otherwlse .

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the forklift will have to back up to the open end of the row and spend extra time in so doing.
In practice two rows of these racks are normally placed back-to-back to take advantage of the enhanced stability resulting from this type configuration. A
typical example of such an arrangement is shown in Figure 1. Moreover, one aisle spacing is saved that would be needed if the double row of racks were separated into two single rows. This back-to back rack system i~ cla~sified as a "Single Deep Selactive Rack Sy~temn. As shown in Figure 1, pallet loads 10 are placed one deep into each rack space of two adjacent racks 12 and 14, and only one single deep rack space is accessible from the aisles 16 and 18 on either side of the rows of racks for stock replenishing or for order selection.
; The problem with the Single Deep Storage Rack system is it is wasteful of valuable warehouse space. Efficient space utilization is not only a function of amount of warehouse area used for aisles vs. racks, but is also a function of rack space utilization. For example, when a truck load of twenty pallets of case goods arrives they will be stored in twenty rack spaces. Defining a vertical column of rack spaces in the rack row rom which product i9 picked as a ~facingn, each facing will have room or four to five pallets set individually one over the other. A
truck load of pallets could use four or five facings. As order picking progresses, rack spaces become empty and stand vacant until the next truck load arrives.
Furthermore, in the Single Deep Storage Rack system, facings used for truckload storage extend linearly along the row of racks, which means that the order picker must travel longer distances from item to item if an item occupies multiple facings than if the item occupied a single facing. With items requiring multiple facings, one facing is picked until empty, the others stand static until this happens.
As orders are picked from these racks, the racks are 2~)1755~

progressiv~ly empt~ed until they are replenished.
Replenishment occurs as inventories drop to predetermined minimum levels. This happens at different times for different items within the racks. The overall effect is that the racks are never completely full with merchandise.
The occupancy rate, or amount of space utilized at any one time, often exceeds 50~ of available ~pace.
~ "~rive-In ~ack" ~y~tem was then developed whlch not only re501ved the problem of accessing all our rows o the Double Deep Standard Rack system, but opened the way to use multiple rack systems, in excess of four if so desired.
Although not shown, a drive-in rack system involves placing pallets between uprights on load rails which are perpendicular to the aisles rather than on load beams parallel to the aisles. A forklift with a pallet load of packaged merchandise drives into one of the multiple rack passageways, positions the pallet in the deepest accessible pallet space that i~ can reach, then backs out.
In order to improve warehouse space utilization by increasing space used for racks and decreasing space used for aisle~, and at the same time reduce statlc storage facings on the plcklng alsles, a "Double Deep Standard Rack" system was devised as shown in Figure 2, consisting of four rows of racks 18, 20, 22 and 24 joined together.
There is an aisle 16 and 18 on both sides of the rack system from which two-deep rack ~paces 26 and 28 are accessed from either aisle. A special forklift, not shown, with a reach mechanism is necessary to reach the inner rack spaces. In this system, the inner rack is used for static storage, whereas the outside rack is used for order picking. The double deep system as well as those described above use standard rack components for rack construction.
The advantages of the Double Deep ~tandard Rack system are space saving, improved stàtic storage, improved facing exposures, and decrease in linear travel for stock replenishment and for order picking. The disadvantages of the Double Deep Standard Rack ~ystem are the need fol:

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speclal equipped forkllEt~, re~trictlon on ability to reach into the four aonsolidatea row~ of racks 18,20, 22, 24, bo only two deep from each aisle, and each set of two deep racks must hold the same product.
S Disadvantages to thls type of sy~tem are that more space i~ r~qulred between load~ ~han the s~andatd rack conelguratlon~ loadlng thQ raaks must occur rom baak to ront by loading one stack hlgh a~ a tlme startlng from the floor and progresslng to t~e highest level or vlce versa, ~tartlng from the back of the rack~ and working towards the front. Once loaded, access to the next row deep must walt until the entire front "face" 18 removedl and the system makes it almo~t mandatory that the same product be stored ii wlthin each passageway, because replenlshlng any level with a dlfferent product would requlre maklng space available or forkllft access. Furthermore, when a new shipment arrlves, it mlght be placed ln front of the re~ldual prerious ~hlpment which would prevent proper stock rotatlon according to the prinalple of flrst ln-flr~t out. The oaaupancy factor, or peroent utllizatlon of ~vallable rack sp~ae, will ~verage around 50 percen~.
The foregoing type o rack storage, howérer, does not lend ltself to "family" geoupings, where a group of simiiar products are combined into classes of product~, like soups, soaps, breakfast cereals, aOg food, etc. Merchandlse is usually stored into groups of: (a) bigh movement, (b) medlum movement, and (c) low movement. Products from familles may be found in all these three mover categories, which means that they are spread around the warehouse.
A "Drive-Thru Rack" system was then devl~ed to increase the flexibllity of the Drlve-In Rack system. This allows access from either side permitting the two opposlte faces to be working 'until the immediate front adjoining stack of pallets are e'mptied or removed. - Both Drive-Thru .. , .. ~ . . .
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:
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Z01~559c and Drive-In systems require all vertical stacks of pallets stored in the same passageway or throughway, to hold the same product. This applies both to the working faces and to the static backup stacks positioned within the interior of the racks.
The disadvantages of the Drive-Thru Rack system are the same as the Drive-In Rack system discussed above. The system is still subject to improper stock rotation from putting fresh ~tock in front of older stock~ but to a lesser degree, since access for order picking is posslble from two opposite ace ends. The occupancy factor for the Drive-Thru Rack system is somewhat better than the Drive-In Rack system but is still in the order of 50-60%.
The Drive-Thru Rack system, furthermore, does not lend itself to family grouping of merchandise.
To further increase the flexibility of the compacted rows of stacks, a "Pallet Flow-Thru System" was next introduced as sbown in Figure 3, wherein rollers 30 were placed on load rails 32 which were sloped in such a way that multi-level pallets 10 placed on the high end would roll by gravity to the low end where picking takes place.
When one pallet 10 is emptied and removed, the next pallet 10 rolls into place, so that all picking pallets are on the out8ide and the same side o the rows of racks. The use of this system permits each level in the stack to carry a different item if so desired.
Another gravity flow system currently in use is known as the ~Pallet Push-Back Rack" system and is shown in Figure 4. There pallets 10 are pushed uphill on sloped rails 32 from the low side next to aisle 16. When the lowest pallet 10 is used up and removed, the pallets above it roll down by gravity to the front on the rack. ~owever, if product is replenished before all pallet loads move to the picking face 34, the push back-system places new product in front of older product and this system as a consequence loses its flexibility to properly rotate stock on a ~first in - first out" basis.

20~75591, While both the Flow-Thru and Push-Back systems have better occupancy rates, these systems do not lend themselves to "family" grouping and are best suited for storage by "movement" categories.
Prior to the subject invention, each row of racks were configured with the same type rack e.g. Single-Deep Storage Racks, Double-Deep Storage Racks, Drive-in Racks, Drive-Thru Racks, Pallet Flow Racks, and Push-Back racks. Use of two or more different types of racks within a warehouse require a 9eparate 8et of rack row5 for each sy~tem u~ed.
Each system was designQd to address a particular need~
however, they lacked the flexibility to handle the storage varlables dictated by consumer demand and reflected in the rate of consumption quantified by movement values for each item.
This now leads to a consideration of the subject invention. Every one of the tens of thousands of items in a distribution center must be positioned on an outside face of a rack system to make it readily available to picking crews for filling orders. Order selection has to be done in the shortest time possible which is conducive to using picking crews more efficiently so that the number of order pickers can be held within realistic limits to hold picking co~t~ down. To accomplish thi~, the location of the ltems have to be programmed in such a way as to minimize travel distance and consequently travel time through the distribution center complex. Significant savings in time and labor costs result when this is done properly.
Records are kept of inventory "movements" where a movement is defined as the ratio of sales over inventory, and where sales is considered synonymous with movement.
"High movement" items may be picked each time an order comes through,"medium movement" items are required less often, and "low movement" items may only be needed periodically. Some high movement items may require more storage space because of their higher rate of use. The frequency of reordering, the amount ordered, whether 2~ i5~

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truckload lots or split or mixed shipments, and rack space requirement~ for ~torage and for picking are all interrelated with each item's inventory and sales characteristlcs.
Referring now to Figure 6, during order plcking, an order selector or picker has a set of pre-determlned stop polnts 34 wheee he ~tops hls truck 36 and walk~ up and down the ~lsle~ to ~elect ltems as per hi~ order plcklng document. He caerles them back to h1s truck and dr1ves to the next stop polnt. He repeats thl8 sequence untll he has completed hls order selection. Figure 6 further lllustrates a chart of the stop-polnts ln a hypothetlcal n Z
pick" warehouse situation.
It has been found that by gro;uping storage items according to their movements, walking dlstances can be ; décreased and tlme for plcking signlflcantly reduced.
It has also been found that grouplng ltems by famlly as well as by movement that the number of stops may be reduced and tlme for plcklng signlficantly reduced. Additionally, it has been found that intermixing the rack systems by type and by s1ze and by applying the princlples of the invention descrlbed hereln that the occupancy rate 1~ ~lgnl1cantly increased resultlng ln ~uperior and more economlcal use of avallable storage space.
Accordingly, this lnventlon ls directed to a storage rack conflguration comprised of an lntermix of dlfferent types of known rack systems in the same row for increasing the flexibility of storage and retrleval operatlons whlch results in savings in time and labor costs. Figure 5 shows one such arrangement of mixed racks utilized, for example, in the layout depicted in Figure 6.
Referring to Figure 6, there is shown a picking scheme for three movement frequency levels A, ~ and C which stand for "high movement", "medium movement" and "low movement", 3~ respectively, and each having its own specific rack type which is further shown in Figure 6- It can be seen that there 18 a repetltive set of racks for each truck ~top 34 : " : . ~

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11 .
with a picking range for each stop being defined by the distance between points 38 and 40. Each distance span between points 38 and 40 includes the three movement frequency level rack types which repeats itself. For example, beginning at point 38 and moving forwardly, there are three C (low movement) racks followed by three B
(medium movement) racks followed by a slngle A ~hlgh movement) rack whlch 1~ followed by two C ~low movement) racks to the polnt 4~. Fur~hermor~, each truck stop 34 18 at the forward end of the A type rack and the first o the last two C type racks. From this stop point, the operator carrylng out the order selection thus posltions the length of his truck immedlately adjacent the hlgh movement A rack and one or more of the medlum movement ~ rack~, whlch enables hlm to qulckly and efflciently make the requlred selectlon of items. It can be seen that the low movement C
racks are located on either side of the high and medlum movement racks A and B. Accordlngly, as the picker advances to each stop point 34, he flnds the same repetitlve grouplng of rack types.
The type of racks employed in the A, ~, and C group as shown ln Flgure 6 is further shown in Flgure S where the high movement A and medium movement ~ are comprised of push-back storage racks and more partlcularly two-deep, four-hlgh push-back racks 42 whlle the low movement C racks are comprised of, for example, flve and six.high selective eacks 44, 46, which face the same aisle. To the rear of thls rack grouping, one finds A or B type push-back racks 42 behind the C type selective racks 44 and 46, with selective racks 44 and 46 behlnd the push-back racks 42.
This is the arrangement shown in the plan view of Figure 6.
Figures 7 and 8 are illustrative of a second rack configuration and are basically the same as that of the embodiment shown in Figures 5 and 6 with the exception that periodically a fourth type D rack, comprising a flow-through rack, is included in the group of A, ~ and C rack type~.

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As shown in Figure 7, a three-deep, four-high flow-through rack 48 is shown located adjacent an A or B type push-back rack 42. In the plan view layout of a warehouse utilizing this arrangement, it can be seen that D type racks 48 typically appear adjacent alternating locations of high movement A type racks 42, which due to the back-to-back configuration, is located adjacent a low movement C
type rack of the next aisle. It should be noted, however, that when desirable, flow-through D type ràcks 48 can be selectively intermixed in any required pattern and therefore the layout shown in Figure 8 is only meant to disclose a typical example since it is possible to set up any combination o double deep A or B type push-back racks and flow-through D type racks, depending upon the needs of the particular user.
It is further possible to change from one rack type to another or combinations thereof if and when needed. For the configuration shown, for example, in Figures 5 and 7, the time for changeover from one rack type to another can be made in approximately one hour for a single rack section. It is also possible to configure more than three rows of condensed stacks and use the variable stacking pattern as for the three row configuration as dl~closed.
Having thu~ shown and described what is at present considered to be the preferred embodiments of the invention, it should be noted that the same has been made by way of illustration and not limitation. Accordingly, all modifications, alterations and changes coming within the spirit and scope of the invention are herein meant to be included.

Claims (15)

1. A warehousing method, comprising the steps of:
arranging a plurality of different types of storage racks into repetitive sets of racks, each set including at least one high movement rack of a predetermined type at the forward end of the set; a plurality of medium movement racks of a predetermined type adjacent said high movement rack and being greater in number than said high movement rack; and a plurality of low movement racks of a predetermined type adjacent said medium movement racks at the rear of said set and being greater in number than the number of said medium movement racks;
defining a picking stop adjacent said at least one high movement rack on each set of racks;
selectively loading items onto said storage racks depending upon the frequency of movement anticipated; and retrieving or picking items from said storage racks to fill an order upon arriving at a said picking stop;
whereby by selectively grouping storage items into frequency of movement, an order selector can stop at said picking stop and select items to fill an order more efficiently by reducing the walking distance required and according to the time for filling an order.

2. The method as defined by claim 1 wherein said at least one high movement type rack comprises a push-back type rack, said plurality of medium movement racks comprise push-back type racks, and said plurality of low movement type racks comprise selective type racks.

3. The method as defined by claim 2 wherein said plurality of medium movement push-back type racks comprise at least three push-back type racks and wherein said plurality of low movement racks comprise at least four selective type racks.

4. The method as defined by claim 1 wherein said step of defining a picking stop further comprises defining a picking stop, of intermediate sets of said sets, adjacent said at least one high movement rack of said intermediate sets of racks and the last low movement rack of a succeeding or next set of said intermediate sets.

5. The method as defined by claim 4 wherein said step of retrieving comprises selectively retrieving items from said storage racks on both sides of said picking stop of said intermediate sets to fill an order.

6. The method as defined by claim 4 wherein said step of arranging additionally includes the step of interposing a flow-through type rack between said at least one high movement type of rack at the forward end of a set of said intermediate sets and the last low movement type rack of a succeeding or next set of racks of said intermediate sets of racks.

7. The method as defined by claim 6 wherein said step of defining a picking stop comprises defining a picking stop adjacently between said at least one high movement rack at the forward end of a said intermediate set and said flow-through type rack.

8. The method as defined by claim 7 wherein said step of retrieving comprises selectively retrieving items from said storage racks on both sides of said picking stop to fill an order.

9. The method as defined by claim 3 wherein said step of arranging said storage racks comprises arranging said sets in rows of storage racks in a back-to-back linear configuration so as to face a respective different aisle in a warehouse.

10. The method as defined by claim 9 wherein said back-to-back arrangement of racks comprises locating said low movement selective type racks behind said at least one high movement push-back type of rack and said plurality of medium movement push-back type of racks.

11. A method for warehousing packaged goods, comprising:
arranging a plurality of different type racks in a predetermined set of racks adjacent an aisle in a warehouse, said predetermined set of racks including a high movement push-back type of rack group, a medium movement push-back type of rack group, and a low movement selective type of rack group;
locating a predetermined stop point on said aisle in proximity to said high movement rack group;
loading items onto said storage racks in a predetermined order as a function of expected retrieval frequency; and retrieving or picking items from said storage racks upon arriving at said picking stop to fill an order;
whereby by grouping storage items by their frequency of movement, an order selector can stop at said stop point and select items to fill an order selection, thereby reducing the walking distance in time for filling an order.

12. The method of claim 11 wherein said high movement rack group comprises a single push-back type of rack, said medium movement rack group comprises at least two push-back type racks, and said low movement rack group comprises a number of selective type racks greater than the number of said medium movement racks.

13. A warehousing method, comprising the steps of:
arranging a plurality of different types of storage racks into repetitive sets of racks, each set including at least one high movement rack of a push-back type at the forward end of the set;
a plurality of medium movement racks of said push-back type adjacent said high movement rack and being greater in number than said high movement rack; and a plurality of low movement racks of a selective type adjacent said medium movement racks at the rear of said set and being greater in number than the number of said medium movement racks;
defining a picking stop adjacent said at least one high movement push-back type rack of a set of racks and the last low movement selective type rack of the next forward set of racks;
selectively loading items onto said storage racks depending upon the frequency of movement anticipated; and retrieving or picking items from said storage racks to fill an order upon arriving at a said picking stop;
whereby by selectively grouping storage items into frequency of movement, an order selector can stop at said picking stop and select items to fill an order more efficiently by reducing the walking distance required and according to the time for filling an order.

14. The method of claim 13 wherein said arranging step additionally includes locating a flow through type rack between a selective pair of adjacent sets of said sets of racks.

15. The method of claim 14 wherein the method for warehousing packaged goods, comprising:
arranging a plurality of different type racks in a predetermined set of racks adjacent an aisle in a warehouse, said