TABLE OF CONTENTS The first factor that has an influence on design of a small-item or flatwear apparel manual order-fulfillment operation is the building area for the pick and pack activities. This area houses the most important order-fulfillment activities. The receiving, storage, shipping, IT, and other administration areas are support functions to the pick and pack activities. The size and shape of the site dictate facility design. The best design for a small-item or flatwear manual order-fulfillment operation is in a square or rectangular facility. The buildings have 10 to 13 ft. between the floor surface and ceiling support structure. The pick and pack area layout should be designed so that pick aisles and pick position rows are parallel or perpendicular to the pack stations, and there is a queue area for CO picked pieces, as well as a transport path from the pack area to the carton manifest and shipping area.
The shape of a small-item order-fulfillment facility has significant impact on the arrangement of the pick position, pick line and pick aisles, pack area, space utilization, and the flow of vendor-delivered UOPs and CO pieces through the facility. When the shape of a facility site is not square or rectangle, there is low utilization of land space and internal building space. A square or rectangular facility is set on a site with the land angle sections providing the best land utilization, green area, or set back from...
