Zone Routing Systems represent the next evolutionary step step in
zone picking operations. The key element in a Zone Routing System is the PoDD©
(Point
of Destination Decision).
As you recall from the previous diagram, a Zone Routing System
layout is very similar to a Pick to Tote or Pick to Carton order selection system. A
center powered live roller "take-away" conveyor with outboard gravity conveyor
"flankers" located on either side.
Conventional sequential picking systems typically have picking
operators located on each side of the conveyors who will walk the length of the conveyor
picking product, placing it into totes or empty cartons, and when an order is complete
they will push the tote onto the take-away conveyor. The operator returns to the starting
point to start a new order.
Zoned picking systems work in a similar fashion except, that
operators are "confined" to specific areas. These systems operate in a manner
similar to a "bucket brigade" with tote handed from one operator to another. An
operator will look into a tote entering their zone, examine the order document, pick the
proper product into the tote and then escort the tote to the next zone, unless the order
is complete. If an order is complete, the operator pushes the tote onto the take-away
conveyor.
