Selecting the right sorting method takes a bit of planning but can be accomplished with relative ease.
Various methodologies may be employed in your workflow. Remember, this isn’t one-size-fits-all. Sometimes it pays to switch it up!
Wave vs. Batch Sorting:
Bulk Sorting
Inventory is inducted onto the sorter in bulk to fill orders for a specific time period/wave. Induction is accomplished by using the most appropriate method (either automatically or manually or a combination of both) .
This is how wave sorting works:
Orders are received up to a decided cut off time. Your WMS then creates a file of all products and quantities needed to fill those orders. A runner(s) would then go to the appropriate storage areas to gather the bulk requirement for each product necessary to complete the requirements of the cutoff. The collected product is then brought to the sorter for distribution to each designated drop according to the order requirement. Once the product has been fully induced all the orders are complete and the next wave is ready for induction.
Waves may also be treated by separating the right half and left half of the sorter for alternate cutoffs.
The sorter comes with an option to verify that the product is dropped to the correct location and to match all products dropped against the order. Deficiencies could be reported to the operator for completion or override before proceeding to the next wave. An automated take-away and replenishment system may also be installed to reduce downtime when transitioning between waves.
If uniformly sized shipping boxes are used, the sorter can be designed to drop product directly into the shipping carton.
Continuous Wave Sorting
Another method is to sort on a continuous basis rather than in waves. In this case, the sorter is always running and continuously being reconfigured for the next drop after the previous order has been completed and removed.
This method requires more sophisticated software and controls, as well as an automated take-away and replenishment system described above to ensure the uninterrupted flow through the sorter. All methods require that all products be bar-coded for identification.
Multiple Batch Sort • Simultaneous Batch Sort
This mode of operation is like the wave mode in that product is brought to the sorter in groups or batches (waves) see wave sorting. However, it differs from the wave sorting in that there are multiple batches or waves configured on the sorter at the same time.
Using an example of two batches (waves) on a straight, or in-line sorter, one batch (wave) could be configured on one side of the sorter and the second on the other side. One batch or wave of bulk product is brought to the sorter at a time so that one side of the sorter can finish its sort before the other one begins. This method allows the sorter to work continuously since product is always being loaded. Transition time between waves is almost eliminated making more efficient use of the equipment.
This method is employed when it is important to get a greater throughput from the equipment and the sorter is large enough to create efficient bulk pulls of batches or waves for partial segments of the sorter.
Small Orders, E-Commerce and Omni-channel
This mode of operation addresses the challenge of sorting various order sizes and SKU mixes. Orders are batched in waves the same way as with the other modes. The difference here being many orders of few SKUs (wide and shallow order make-up).
Normally, if all the orders were composed of only few pieces per order a sorter would not seem appropriate since a sort to 100 orders of only three pieces each (300 total) would be completed in a minute and a half! However, most distribution centers must address both the institutional buyer as well as the direct to consumer market. The solution entails the merging of two technologies and consolidating orders.
It works like this. For the most part, the 80:20 rule applies where 80% of the volume is made up from 20% of the SKUs. The trick is to consolidate small orders to a single combined chute while larger orders have their own dedicated chute. The common SKUs across both larger orders and smaller orders are pulled together and separated by order. Only in the small order chute they are combined with other small orders.
As a result, the batch pick is optimized, the sorter usage is optimized, and smaller orders were processed through the normal process. Now, it is only necessary to separate out the individual orders from the consolidated grouping. This is where Put-to-Light comes into play.
As the product for the group of orders begins to accumulate in the sorter chute, the operator would scan each piece and put the item to the order using the Put-to-Light. The sorter and Put-to-Light systems should be fully integrated so that the order fulfillment process is fluid and seamless.
This consolidation method also works well with products that are of uniform shape and size for automatic or manual packaging, in that the sorter could send products of like size to a single automatic packager for packaging, sealing, weighing and mailing. The idea is that like processes may be combined using the sorter if desirable to do so.
Let GBI help you to optimize your sortation, contact us today.
