Device improves ergonomics on the pick floor for Capital Candy

When people walk into most distribution centers, they will typically find rows and rows of less-than-full pallets inside racks and lots of empty, unused space above the cases. The reasons are clear: Even the tallest order pickers can only reach and bend so far to retrieve bulky cases, and they need extra overhead space so that their heads don’t hit any beams.

Capital Candy knows the challenges of pallet storage and pallet picking all too well, as the wholesaler provides thousands of products for convenience and grocery stores in Vermont, Maine, Massachusetts, New Hampshire and New York.

“We have more than 12,000 SKUs at our distribution center, including perishables on pallets in the cooler areas like 40-pound cases of chicken and 80-pound cases of beef,” says operations manager Jim Thibeault. “We need to make the best use of our space and give workers an easy, safe way to reach the heavier SKUs.”

Capital Candy implemented a picking device that helped transform standard pallet storage into dynamic pallet storage. The device, which is made of galvanized steel and rides on steel roller bearings, can handle 1,500 pounds of product per pallet, and was designed to improve productivity, space utilization and ergonomics on the pick floor. It is designed to attach to any standard 40 x 48-inch pallet with lag screws.

“In one aisle alone, we gained room for 24 additional pallets of product,” Thibeault says. “We’ve also reduced the amount of reaching and bending [that is] required to pick the bulkier items in the coolers.”

Of equal importance, the order-picking device also attaches easily and quickly. Once the worker picks the items closest to the aisle, the picker simply disengages a latch and, in one smooth motion, slides the back half of the pallet to the front position, so that all products on the pallet are accessible from the aisle.

“We’re seeing significantly higher productivity,” Thibeault adds. “The ergonomic benefits are also a real advantage. The product pulls from the front, so the picker doesn’t have to reach in 48 inches, drag the cases forward and bump his head along the way.”

As a result of these ergonomic advantages, during a pilot study, each pick was completed in almost 2 seconds, on average, 9% faster than picks from a standard pallet.

Related Video

Pick-Plank by UNEX

UNEX Manufacturing
732-928-2800