Ch. 8-10 IET 471 Final Study Guide || with 100% Correct
Answers.
Order picking and shipping; picking and shipping correct answers are typically the highest
priority activities for warehouse operations improvement. This is because they are the most
costly activities in a typical warehouse and labor-intensive functions in the warehouse. To
combat the labor intensity, most of the material- and information-handling systems in
warehousing are devoted to the outbound activities. Many of the decision-support systems and
engineering projects in a warehouse are in ___________________.
Order picking; operating programs; increased; labor shortages and high hurdle rates; increasing
staffing or making significant investments in highly automated equipment; reducing correct
answers has become increasingly difficult to manage. The difficulty arises from the introduction
of new ________________ such as just-in-time (JIT), lean, cycle-time reduction, quick response,
and new marketing strategies such as micromarketing and megabrand strategies. These programs
require smaller orders delivered more frequently and more accurately, and more stock-keeping
units in the order picking system. As a result, throughput, storage, and accuracy requirements
have ________________ dramatically. The conventional responses to these increased
requirements—to hire more people or to invest in more automated equipment—are often stymied
by _____________________________________. Fortunately, there are a number of ways to
improve order-picking productivity without
____________________________________________________________. The strategies are
aimed at _____________ the amount of time order pickers spend in their most time-consuming
tasks.
optimizing issue packs correct answers By encouraging customers to order in full-pallet
quantities or by creating quarter- and/or half-pallet loads, much of the counting and manual
physical handling of cases can be avoided both in your warehouse and in your customers'
warehouses. In similar fashion, by encouraging customers to order in full-case quantities, much
of the counting and extra packaging in loose case picking can be avoided.
simplify picking tasks correct answers The work elements in order picking include traveling to,
from, and between pick locations; searching for pick locations; extracting items from pick
locations; reaching and bending to access pick locations; documenting picking transactions;
sorting items into orders; and packing. Each of those work elements may be eliminated with
process changes and/or technology.
combined correct answers When work elements cannot be eliminated, they can often be
_______________ to improve order picking productivity.
Stock-to-picker (STP) systems correct answers ______________________ such as carouses and
automated storage/retrieval systems should keep order pickers busy while a mechanical device
travels to, from, and between storage locations, bringing pick locations to the order picker.
,document picking transactions, sort material, or pack material correct answers Because a person-
aboard storage/retrieval machine is programmed to automatically transport the order picker
between successive picking locations, the order picker is free to
___________________________________________ while the storage/retrieval machine is
moving.
sort material correct answers Picking carts equipped with dividers or totes allow the picker to
________________ during the course of a picking tour.
packing or shipping container; Packing or shipping containers correct answers When an order is
small, say, less than the size of a shoe box, the order picker can sort directly into a
________________________. ____________________________ must be set up ahead of time
and placed on picking carts equipped with dividers and/or totes.
picking zones; picking zone; zone; zone; zone picking correct answers Once we have decided to
pick from primary pick locations, the next decision is whether or not to organize order picking
by assigning operators to _______________. A _________________ is a portion of an aisle,
multiple aisles, or machines (e.g., carousels and ASRS machines) assigned to an operator for
picking. The key distinguishing feature is that the operator is dedicated to a _______, and no
other operator works in that ________. In _________________ operators do not have order-
completion accountability because the lines on an order will be filled from different zones and
hence by different order pickers.
free-form picking; free-form picking correct answers The opposite zone picking is
____________________. In ____________________, order pickers are responsible for picking
every line on each order assigned to them, and they are free to move to any aisle in the
warehouse.
Operator travel time is reduced because operators are assigned to small, dedicated work areas.
Operators become familiar with products and locations in their zone.
Congestion is minimized because not more than one operator is in an aisle at a time.
There is operator zone-accountability.
It minimizes excessive socializing. correct answers The advantages of zone picking are
Workload imbalances correct answers can create bottlenecks, gridlock, and low worker morale.
free-form picking; free-form picking correct answers In ___________________, order pickers
are free to operate outside the confines of picking zones. In ________________, the toughest
decision is whether the order picker should work on a single order or multiple orders during a
picking tour.
single-order picking; picker-to-stock (PTS) systems; order integrity; traverse a large portion;
high; single order; response-time requirements; emergency order correct answers In
_______________________, each order picker completes one order at a time. In
____________________, single-order picking is like going to a grocery store and accumulating
the items on your grocery list in your cart. Each shopper is only concerned with his or her list.
, The major advantage of single-order picking is that __________________ is never jeopardized.
The major disadvantage is that the order picker is likely to _________________________ of the
warehouse to pick a single order. Consequently, the travel time per line item picked is _______ if
the order does not contain several line items. (For large orders, a _______________ may yield an
efficient picking tour.) However, in some systems, __________________________ do not allow
orders to build up in queue to create efficient batches for order picking. For an
_______________, the customer-service motivation should override the efficiency motivation,
and we should pick the single emergency order without batching.
Batch picking; several orders; number of orders per batch; Single-line orders; Single-line orders;
time; picking errors correct answers _______________ can be thought of as going to a grocery
store with your shopping list and those of some of your neighbors. In one traversal of the grocery
store, you will have completed _____________. As a result, the travel time per line item picked
will be reduced by approximately the ______________________________. For example, if an
order picker picks one order with two items while traveling 100 feet, the distance traveled per
pick is 50 feet. If the picker picked two orders with four items, the distance traveled per pick is
reduced to 25 feet. __________________ are a natural group of orders to pick together.
_________________ can be batched by small zones in the warehouse to further reduce travel
time. The major disadvantages of batch picking are the___________ required to sort line items
into customer orders and the potential for _______________.
order integrity; progressive order assembly and downstream sorting correct answers The major
decision in zone picking is how to establish ___________________ for orders with lines picked
in multiple zones. The two options are ____________________________________.
progressive assembly (or pick-and-pass) systems; progressive order assembly systems correct
answers In ________________________________, the contents of an order are passed by hand,
conveyor, or vehicle from one zone to the next until the order is completely assembled.
Sophisticated __________________________________ employ zone skipping, transporting an
order's container to a zone only if there is an SKU for the order in that particular zone.
Order pickers; Product; sorting system; cost of downstream sorting systems correct answers In
zone picking with downstream sorting: ______________ work in parallel, making full passes of
their pick zone during a wave. _____________ is typically bar-code labeled as it is picked and
placed into a large cart or onto a conveyor belt that passes alongside the pick line. The contents
of the cart and/or the items on the take-away conveyor are inducted into a _________________
that sorts the merchandise into customer orders. The _______________________________ can
run into the millions of dollars. Hence, the incremental benefits of zone picking with downstream
sorting compared with progressive order assembly must be sufficient to justify the incremental
investment. The incremental benefits are primarily picking productivity benefits. The
incremental cost is the difference between the cost of the material- and information-handling
systems required for downstream sorting versus that required for passing orders from zone to
zone.
U-shaped warehouse layout correct answers A traditional __________________________
includes receiving docks, receiving staging, receiving inspection, put-away to reserve storage,
