Order Consolidation Systems - Analyze & Install

Consolidate Orders from different zones

Powerful boost to productivity, dramatic shipping cost reduction

Consolidate orders into right-sized shipping cartons to reduce shipping costs
Do quality assurance and labeling at order completion workstations on the 'Pull" side.
Trap problem orders for immediate awareness and resolution
Boost productivity with easy and systematic order consolidation from different pick zones
Use this system concept for large scale assembly kitting.
Alternate uses include routing and special handling.

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Order Consolidation Systems - Analyze & Install

Put-to-light to accumulate order. Pull-to-light the completed order.

Accumulate Order Until Complete

Sort and Stage for Order Consolidation and QA

Resolve zone picking inefficiencies where consolidation and QA is an issue.

Sort and combine cartons and totes for a single order into easily identifiable location.
When the order is complete, pull all parts of it to a Quality Assurance workstation.
The IIS / EDGE WCS consolidation module manages the process and integrates to the ERP or WMS routing table.
Provides for complete order component tracking.

Operator directed Put-to-Light for Accumulation

Feed the Put Side of the Consolidation Module from conveyor or carts

By scanning totes and cartons arriving in the Consolidation Area, the associate at the Put Wall is shown the lane to accumulate the order in. This enables the efficient accumulation of totes and cartons for each order that has more than one tote/carton. And puts them into one or more Lanes in the Consolidation Area.

Operator directed Pull-to-Light when Order Complete

Use Consolidation Module for pre-pack staging incomplete orders

Pull order, QC and Pack according to priority: Pull-to-light the directs packer to pull and pack next when more than one order is ready. Pack into right sized cartons, label and track the contents of every carton.

Quality Assurance / Packing workstation

Efficient Work Station, order complete confirmation, correct item and quantity check

From this Pull side workstation, the associate can cross reference via bar code and inspect the intended order list (in the WMS) for completeness. Because the carton contents is confirmed, a predicted weight is available for validation against actual weight in the manifest process.

Control run away shipping costs by right sizing cartons

Consolidate instead of shipping as picked / packed by zone,

Optimize shipping carton size with consolidation
Avoid excess shipping costs which can make or break an operation
Efficient quality assurance checking

Accumulate to consolidate parts of orders in flow lanes as directed.

Pull completed orders on the Quality Assurance / Packing side.

How IIS can help your operation:

Analyze, specify, furnish, install Consolidation Systems

IIS provides turnkey solutions that boost your DC's performance.

IIS provides Consolidation Module specification and engineered design services based on your historical and projected needs.
We furnish and install the Consolidation Modules including Put / Pull to Light based on the engineered design.
IIS/EDGE offers a robust WCS (Warehouse Control System) to drive the routing and directed picking processes throughout the distribution center including the Put and Pull to Light processing system. We proudly team with Lightning Pick for reliable displays.
Integration is our middle name: We work with your operations and IT teams to specify and implement the interface to your WMS or ERP.
Beyond our solid warranty we offer support agreements that include additional training at every level as needed to continually improve the metrics in your operation.
The Consolidation Area enables the efficient accumulation of Totes and Cartons for Deliveries with more than one tote/carton into a lane or lanes in the Consolidation Area. Once all Tote/Cartons associated with this delivery are accumulated, control of this Lane is passed to the Pull side of the system. A system of Green lights and Message lights guide the Pull-Side operator who will then proceed to do quality checks on the order and consolidate these multiple totes and cartons into cartons for outbound shipping.

The green task lights shown in a PULL WALL test sequence at system start up.