Order Picking with Conveyor and Sortation Systems

MAVs deliver a lot of benefits, including higher efficiency, productivity, safety, and flexibility. To provide safe, efficient, and cost-effective movement of materials. To supplement or replace manually-operated material handling vehicles, such as forklifts, tuggers, and order pickers. For greater flexibility in material transport compared to fixed solutions, such as conveyors. In response to shortages in labor, allowing reassignment of employees to areas where they can add more value. To eliminate associate travel time during picking and order fulfillment.

The Protective Guarding Manufacturers Association (ProGMA) has published a blog to supplement its latest video on safety at pick modules. The video can be viewed at mhi.org/progma/videos.Here at ProGMA, we have produced a series of educational videos on protective guarding equipment in the material handling industry. ProGMA members provide fixed protective guarding products to protect personnel, equipment, and inventory in industrial facilities. A variety of such items are designed for installation at pick modules, which are multi-level structures typically constructed out of pallet rack that allow multiple pallets of product to be stored, broken down, picked, and packaged into specific orders for shipping.Our video is targeted at end users, system integrators, material handling warehouse design consultants / engineers, distributors, and safety professionals in manufacturing and distribution centers in the material handling industry, as well as students studying the sector. Many household and industrial goods we interact with every day were once stored or passed through a pick module. At the distribution centers of companies like CVS Pharmacy and Rite Aid Corporation, for example, goods are stored before being repackaged and shipped to individual stores.As the 2:23min-long video says at the outset, pick modules can have several elevated levels of materials that are handled by both automation and personnel. Although everything in the material handling industry is becoming more automated, separation of full stored cases into smaller, individual shipments is still being completed manually. The size of pick modules has been increasing over the years; in the past, you may have seen a floor plus one level system, then a floor plus two levels, and now it is not uncommon to see three or even four elevated levels. This increases potential hazards.As the video continues, it is of paramount importance that proper guarding is used from the ground up to protect structures, the product they hold and, most importantly, the people working within and around them. Rack upright columns can be difficult to replace and costly to repair because often the area has to be closed off, product has to be removed, and multiple sections need to be disassembled. These components are all dependent upon one another, so if one part fails, the entire system can fail.The video highlights three “easy and affordable” solutions: Free-standing pallet rack column protectors Post cushions Bumper guardsHowever, ProGMA members offer a variety of products for ground-level protection including guardrails, bumper guards, column protectors, bollards, rack guards, and product containment enclosures  (i.e., wire mesh or netting); and for upper-level protection, such as side and back product containment enclosures (wire mesh or netting) to prevent products from falling below.What does ANSI say?The video continues, and quotes American National Standards Institute (ANSI) 6.4.3, which states that “…any gate that provides an access opening through the guards for the purpose of loading and unloading material onto a work platform shall be designed such that the elevated surface is protected by guards at all times. Gates that swing open, slide open, or lift or leave an unprotected opening in the guarding are not acceptable.”However, it is important to note that there are many mezzanines that were installed before the ANSI standards were created that used more conventional gates, such as removable, sliding, or swinging systems—and that is the same for pick modules. Systems can be retrofitted to achieve conformity with current standardization. There is no grandfather clause for ANSI (or OSHA) so all systems whether new or old should follow their guidelines. Note that many of the protective guarding products found in the video and on the ProGMA site are easily retrofittable to these older systems.As the video stresses, only dual-gate systems should be used. The same gates used on a pick module are also the preferred method for securing all elevated pallet drop areas whether they are in pick modules, on mezzanines, or on elevated work platforms such as storage or production / blending areas. The ANSI standards that recommended the use of dual-gate systems were written specifically for elevated work platforms and since a pick module is a type of elevated work platform that should be applied.The video demonstrates how a dual-gate system uses two counterbalanced and interconnected gates that are configured so when the first gate at the ledge is open, the second gate behind the pallet is closed. Fixed guarding on the sides—often the frame of the pallet rack in a pick module—prevents access into the side of the areas. This allows material to be loaded into the area while keeping employees a safe distance from the ledge and the material. When the rear / operator gate is opened, the ledge gate automatically closes, maintaining a barrier at the ledge while the pallet is accessed and picked. This creates what ProGMA calls a controlled-access area so there is always a barrier between the worker and the ledge.For information, ProGMA members that manufacture such solutions include Mezzanine Safeti-Gates Inc., Wildeck, and Heartland Engineered Products. Although companies still provide swing gates for pallet drop areas where a single pallet is loaded and staged, they are not an acceptable solution according to ANSI and could potentially create a situation where they are in violation of OSHA code.A self-closing swing gate, also featured in the video, should only be used when integrated with pallet flow lanes where multiple pallets are loaded into the system. The pallet flow lanes are pitched so the pallet rolls into the storage area. This allows the gate to immediately close once the pallet is loaded.  By comparison, when used for a single pallet position without flow rails, the staged pallet would hold the swinging gate open, preventing it from closing.For securing multiple deep pallet flow lanes, a dual-gate system is the preferred safety method because not only does it make sure a barrier is in place all times for fall protection, but it also keeps people out of the pallet flow lanes when pallets are being loaded. The two types of incidents we see in these areas are falls from the ledges and pallets being pushed into the legs of employees who have entered the lane. Only the dual-gate system keeps people out of the lanes when the lane is being loaded. The self-closing swing gate, however, does secure the ledge for fall protection.Hand in gloveOftentimes, a safety aspect can be used to increase productivity. For example, the self-closing swinging gate on pallet flow lanes will allow pallets to be quickly loaded into the system. Any time the lift truck operator wants to load a pallet into the area, they just push the pallet through the swinging gates. The dual-gate system has the potential of the gates being in the incorrect position for loading, meaning that the ledge gate is closed when the lift truck is trying to replenish pallets into the area. So they can go to load but a barrier is in place preventing them from doing so.A user can power operate these gates for remote operation but often this isn’t feasible due to the number of areas. Manual operation can actually create a safer and faster environment. The position of the gates in a dual-gate system can be used as a signal between the picker up on the platform and the lift truck operator below. In other words, when the ledge gate is closed that means the picker is picking from the pallets or the area doesn’t need to be replenished.When the picker has finished in that bay or when they notice the pallets need to be replenished in that bay, they just manually close the gate near them, which opens up the ledge gate. Now the lift truck operator can look up and see which areas are safe and ready to be replenished. This is an example of a safety system helping communications among the different workers.In conclusion, it’s evident that, despite automation, people remain at the center of activity in and around pick modules. ProGMA and its members are a one-stop-shop for leading safety solutions, whether it be for preventing hazards associated with falling boxes, product, or workers; or structural protection of the system itself from impact. As the video serves to reiterate, even in automated systems there are still people moving around the facility, either on ground level or on the elevated levels. Even if people are not used for the picking of material, there are areas where empty pallets or totes are removed that need to be guarded.The product-centric video doesn’t feature specific brands, but free-standing pallet rack column protectors, post cushions, and bumper guards are available from ProGMA members including Adrian’s Safety Solutions, A-Safe USA, Bluff Manufacturing, Boplan, DamoTech, Folding Guard, Husky Rack & Wire, Heartland Engineered Products, Jesco, McCue, Slowstop Guarding, SpaceGuard Products, Steel King, Troax, VisiPlas, Wildeck, and WireCrafters.Costs range from inexpensive, light-duty products to more expensive, heavy-duty solutions. Importantly, talking with the manufacturer about the application will help source the right product/s for the facility. No two pick modules or applications are completely alike and that’s what the member companies of the ProGMA are here to help with.The ProGMA website—mhi.org/progma—features details of 22 member companies and hundreds of solutions to help companies with older systems find protective guarding solutions to update / upgrade their pick module system.See the latest video and others in the series at mhi.org/progma/videosShould you be using a ProGMA member to enhance the safety and productivity of your pick modules?About ProGMAThe Protective Guarding Manufacturers Association (ProGMA) members are the industry’s leading suppliers of fixed protective guarding products designed to protect personnel, equipment, and inventory in industrial facilities. Member companies meet regularly to review, discuss, and revise the standards for design and performance of protective guarding products used in the material handling industry. ProGMA member companies are committed to the development, maintenance, and publishing of industry standard specifications for these systems. Visit the website at mhi.org/progma.About MHIMHI is an international trade association that has represented the material handling, logistics and supply chain industry since 1945. MHI members include material handling and logistics equipment and systems manufacturers, integrators, consultants, publishers and third-party logistics providers. MHI offers education, networking and solution sourcing for their members, their customers and the industry as a whole through programming and events. The association sponsors the ProMat and MODEX expos to showcase the products and services of its member companies and to educate manufacturing and supply chain professionals.Contact for editorial enquiries: Ashley Skidmore, askidmore@mhi.org or 704-676-1190

WIXOM, MI - ISD - Integrated Systems Design today announced the Robotic 3D Sorter Mini Putwall System, an advanced sortation solution that transforms warehouse operations through its innovative three-dimensional design. The system delivers impressive metrics including 70% labor savings and return on investment in under a year.The 3D Sorter Mini utilizes both vertical and horizontal space to minimize footprint while maximizing sortation capabilities. With a throughput of up to 1,500 pieces per hour and 3 to 5 times greater sorting efficiency compared to manual methods, the system addresses critical challenges facing modern warehouses."What makes the 3D Sorter Mini truly exceptional is its ability to deliver enterprise-level sortation performance in a compact footprint," said Ed Romaine, VP Marketing and Business Development at ISD. "We're seeing clients achieve dramatic improvements in efficiency while significantly reducing labor costs. This system represents a fundamental shift in how warehouses approach the entire sortation process."The system's intelligent design accommodates up to 100 customizable sort positions and integrates seamlessly with existing warehouse technologies, including Autonomous Mobile Robots (AMRs), Automated Storage and Retrieval Systems (ASRS), conveyor systems, and shelving solutions.By automating the sortation process, operations can significantly reduce reliance on manual labor while processing items at previously unattainable rates in comparable spaces. The combination of labor savings, improved throughput, and reduced error rates contributes to the system's notably fast return on investment.In today's competitive real estate market, the 3D Sorter Mini addresses space constraints through vertical design, requiring significantly less floor area than traditional sorting systems. Its modular, customizable configuration makes it ideal for operations experiencing seasonal fluctuations in demand.The system features advanced intelligence with seamless integration capabilities for major Warehouse Management Systems, Warehouse Execution Systems, and Enterprise Resource Planning platforms. Despite its sophisticated technology, the 3D Sorter Mini is designed for rapid deployment with minimal training requirements.Its versatility makes it suitable for diverse applications across numerous sectors including e-commerce, apparel and footwear, third-party logistics, healthcare, and manufacturing. The underlying technology includes high-speed sorting robots operating at 1.0 m/s with vertical lifting ranges from 500mm to 2100mm, intelligent routing, and gentle handling through high-friction conveyor belts.As warehouses face increasing pressure to process more orders faster while controlling costs, solutions like the Robotic 3D Sorter Mini Putwall System represent essential technology for competitive operations. The system's combination of space efficiency, labor savings, and cross-industry adaptability positions it as a key advancement in warehouse automation.About Integrated Systems Design - ISD Integrated Systems Design is a comprehensive systems integrator of automated solutions for warehouses, manufacturing, distribution centers, retail, assembly, and wholesale applications improving processes and productivity while reducing operational costs. Whether providing consulting services to meet current issues or developing future scalable plans to address industry challenges, ISD creates value by designing systems to our clients' specific requirements. ISD expertise ranges from handling, storing, and picking pieces (eaches), cases, pallets, build lines, and special or custom handling solutions. Products and services include: automatic storage and retrieval (ASRS), conveyor, AMRs, robotics, batch stations, shuttles, pick-to-light, carousels, vertical lift modules (VLMs), sortation systems, truck loading/unloading systems, controls, software (including inventory management, WCS, WMS, MES, and ERP).ContactEd RomaineVP Marketing & Bus. Dev.215-512-2613eromaine@isddd.com

Greer, SC—Creform Corporation, a manufacturer of unique products for material handling and commercial use has designed, built and assembled a flow rack for an automotive parts manufacturer that creates a “supermarket” storage area. The flow racks create a storage area ideal for picking parts and kits of individual SKU’s that make up a manufacturing kit. The flow rack is  also ideal for assembly stations, work-in-process storage, kitting operations and can also be used for general warehousing of pull-to-ship parts.The flow rack is used as an individual rack or has the ability to connect several together with brackets in order to create a large-scale picking supermarket. It allows for quick material replenishment and fast access to parts, is scalable and can be expanded or reconfigured as production demand changes.The rack has three levels of gravity-fed roller tracks that provide smooth and controlled flow of containers and incorporates multiple roller track lanes. The roller tracks are rated for continuous industrial use with consistent part presentation and are suitable for a wide range of container weights, from light kitting totes to heavy-duty bins. The flow lanes are angled for reliable container flow and presentation while guaranteeing FIFO inventory management.Each of the rack’s levels can be repositioned or the entire flow rack can be customized with only simple tools while the vertical presentation face allows the levels to be easily moved up or down with the same simple tool.The flow rack features 15 mobile casters for easy repositioning across work zones and is fully reconfigurable — shelves, roller tracks, and lane spacing can be quickly adjusted as your production needs evolve. Designed with ergonomics in mind, the system allows easy customization for different operators or work cells. Stationary structural feet are available as an option.The dimensions of the flow rack pictured are 132" W x 48" D x 63" T and has a maximum load capacity of 2000 lb.Low friction precision Placon skate wheel conveyors are available that allow for shallow flow lane angles suitable for both plastic returnable totes as well as cardboard boxes.As with all Creform flow racks, higher capacity, sizes, configurations and lane dividers are possible. The flow rack pictured is white, but a wide variety of pipe colors are available as well as for ESD applications. Accessories can include information sheet holders, label holders, tool storage, hooks to hang tools and other supplies. Creform flow racks are suitable for warehouse or manufacturing plant use. They are available as a kit or an assembled structure or in the component form for a complete DIY solution.The Creform System is used to create an array of material handling and efficiency enhancing devices and is a proven component in continuous improvement and lean manufacturing programs. The company partners with customers in developing and enhancing these programs.ContactBG EdwardsCreform Corporationbg.edwards@creform.com800.839.8823SCsales@creform.comwww.creform.com

WIXOM, MI, August 2025 — ISD has launched OneTouchDistribution, a cutting-edge automation system designed to optimize order fulfillment for case, split-case, and pallet operations. By integrating state-of-the-art storage, retrieval, transportation and processing technologies, the system minimizes labor requirements, enhances accuracy, and maximizes facility space utilization.OneTouchDistribution provides a comprehensive approach to warehouse automation, offering a seamless process from inbound receipt to outbound fulfillment. The system significantly reduces labor requirements by automating receiving, storage and order processing.By leveraging advanced tracking and sequencing, OneTouchDistribution ensures 99.9% percent pick and inventory accuracy while maintaining high throughput, even during peak demand periods. The system’s high-density design allows for the storage of hundreds of thousands of cases or split-case products in a compact footprint, making it an ideal solution for facilities looking to maximize operational efficiency without expanding their physical space."OneTouchDistribution was designed with flexibility and agility at its core," said Ed Romaine, VP of Marketing at ISD. "Every operation has unique challenges, and our system adapts to those needs… whether handling cases, split-cases, or pallets. It allows businesses to scale seamlessly, adjust to shifting demand, and optimize order fulfillment without disruptions. This level of adaptability ensures our clients maintain efficiency, accuracy, and speed, even in the most dynamic distribution environments."The system automates inbound processing by receiving products through lift trucks, autonomous mobile robots, humanoids or Cobots. Once received, items are scanned, recorded, and directed into an automated storage and retrieval system that organizes and tracks each product in real time.Orders are processed based on specific sequencing and fulfillment requirements, ensuring that inventory is retrieved in the optimal sequence for downstream operations. Retrieved products are sent to fully automated or semi-automated picking stations, where they are either picked and sent to a cartonizing area for split-case processing, directly routed to a sorter for case picking or delivered to palletizing and/or an outbound staging area for final shipping.OneTouchDistribution is designed to support a wide range of industries, including food service, ecommerce, pharmaceuticals, industrial distribution, reverse logistics and third-party logistics. Its scalable architecture allows for phased implementation, enabling businesses to integrate automation at their own pace while maintaining ongoing operations.The system’s ability to handle full-case, split-case and pallet orders within a single platform adds to its versatility, making it a viable solution for distribution centers with diverse fulfillment requirements.The system also offers flexibility in order sequencing, allowing products to be picked and processed in a precise order based on weight, fragility, delivery requirements, order cut-off times, and customer preferences. Automated scanning and labeling ensure complete validation before orders leave the facility, reducing errors and increasing efficiency. Likewise, document printers and inserters can be easily integrated into the OneTouchDistribution system for increased revenue generation and reduced labor.With a focus on space optimization, the system minimizes wasted storage areas and maximizes available cubic space, creating a more efficient and cost-effective distribution process.About Integrated Systems Design - ISDIntegrated Systems Design is a comprehensive systems integrator of automated solutions for warehouses, manufacturing, distribution, retail, and wholesale applications, improving processes and productivity while reducing operational costs. Whether providing consulting services to meet current issues or developing future scalable plans to address industry challenges, ISD creates value for a broad range of industries by tailoring systems to clients' specific requirements.ISD expertise ranges from handling, storing, and picking pieces (eaches), cases, pallets, build lines, and special or custom handling solutions. Products and services include automatic storage and retrieval (ASRS), AMR, conveyor, robotics, batch stations, shuttles, pick-to-light, carousels, vertical lift modules (VLMs), controls, and software (including inventory management, WCS, WMS, and MES).ContactEd RomaineVP Marketing & Business Development215-512-2613

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Many shipping and picking errors can be resolved by automating picking processes and implementing automated audit systems to ensure everything in order is correct before it is sent out. A global manufacturing supply company was looking for a way to automate these processes to ensure correct qualities of its products are shipped to the correct retail store. This supplier was having issues with stock being delivered to incorrect retail stores or delivering incorrect quantities. Prior to involving SICK, this process was manual with no automation, which led to many errors and added costs to resolve issues from these errors.

Stihl dealer in the Midwest can expect fast, accurate service when they need equipment, accessories or spare partsMississippi Valley Saw was founded in 1978 by Bob Joynt in Peoria, IL. It began serving the nation’s heartland by shipping chain saws, log splitters and accessories to about 70 independent dealers and lawn centers. Growth was swift, and in 1981 the company moved into a new location. Soon after, Mr. Hans Peter Stihl visited and asked them to drop all other lines and become an exclusive Stihl dealer. Mississippi Valley Stihl (MVS) was born.MVS investigated all possible solutions to their time, inventory and space issues and chose the Lean-Lift® Vertical Lift Module from Hänel Storage Systems. A bank of three units were installed initially, with a fourth lift added shortly after to keep pace with demand.The benefits of the Lean-Lifts® were immediate. Before the lifts, five or six people would work well into overtime to fill the day’s orders.After the lifts, a single person could get all orders received by 2 p.m. out by 4 p.m. the same day. Orders are picked faster with less walking and no more overtime.The lifts work together to cue the next part automatically so that the operator can move from lift to lift, minimizing any potential wait time for trays to be delivered to the access point. Totes and boxes are used to collect the various parts for each order, with a put-to-light system ensuring the right parts go into the right container. A pick-to-light system is used to pull fast moving items from bins nearby.The increased speed and accuracy afforded by the Hänel Lean-Lifts® allowed MVS to keep its commitment to its dealer network to provide the right part within 24–48 hours, even while stocking an ever-increasing inventory of parts.

The Hänel Lean-Lift as a high-speed shipping systemWhen it comes to tools, the experts at Productivity Inc. can provide customized solutions for the metalworking industry. In addition to consulting, customer care, service and maintenance,Productivity Inc. delivers tools and tool holders to customers throughout North America. Fast shipping from the company’s site in Minneapolis is supported by three Hänel Lean-Lifts® that are used to store more than 10,000 items.The Hänel vertical lifts are equipped with multifunction containers, making them ideal for automated small parts storage. Job orders are displayed directly on the HänelSoft® terminal and can be processed there.The high-speed version of the Hänel Lean-Lift® quickly brings stored items to the retrieval area on request.If the items needed for a particular order are located in various lift systems, picking performance can be boosted even more through parallel system operation.Thanks to digital compartment and sub-level indicators, even storage positions in very small configuration layout patterns can be identified easily. The combination of all these features ensures that orders are filled and shipped in record time – without errors.Orders are filled directly opposite the system access points, where they are also packed for shipping. Order confirmation is entered in the systems using barcode scanners. Another Hänel Lean-Lift® located in a different area of the warehouse is also integrated in the storage solution.Productivity Inc. quickly recognized the high quality of Hänel technology through the reliable performance delivered by the storage systems

Order picking or order selection is the process of retrieving individual items (from storage locations) for the purpose of fulfilling an order for a customer. Schemes by which to achieve efficient order picking will vary widely. However, in all cases it involves locating the items in storage; creating a plan for retrieving the items; physically picking the items (either automatically or manually); sorting and/or assembling them into discrete orders; and in the end even packaging the orders for delivery. Although defined as a process, order picking cannot be achieved without the appropriate computer software and mechanical equipment, including the storage medium, such as pallet racks, shelving, AS/RS (including carousels) and flow delivery racks, and a means for transporting items from receiving to storage and from storage to packaging and shipment. A variety of industrial trucks and conveyors will be found in most order picking applications. Order picking may also involve robotic like devices for physically picking discrete items from their storage location. See also Warehouse Management Systems or WMS .

The combining of a group of order requirements by SKU into a single picking activity to optimize productivity by allowing one picker to select all the ordered merchandise within a predetermined group with one trip through the pick path. Batch picking requires subsequent mechanical or manual sorting of the merchandise to reestablish order integrity before shipping.

A storage system that provides varying means of either mechanically moving storage locations or loads within the systems so as to increase storage density and/or to increase storage, retrieval and order picking throughput.

Fulfillment and Distribution centers have adapted to the increased demand brought on by floods of e-commerce orders. Now, having transitioned to picking eaches instead of full containers, more flexibility is required from conveyor and sortation solutions if operators want to keep up.

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Fulfillment and Distribution centers have adapted to the increased demand brought on by floods of e-commerce orders. Now, having transitioned to picking eaches instead of full containers, more flexibility is required from conveyor and sortation solutions if operators want to keep up.

This document describes the operation, application and benefits resulting from the use of this automated storage and retrieval system.

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