Tote Returns off of Pack Line 1

[JTEngTips]

How do you get rid (return to source) pick totes off of a pack line? We have return bins, but the bins wind up falling out of the back of the 'return' line onto the floor. Is there a way to get the bins handled back to where they can be used?

 

[Ross0684]

All depends on your layout.
Is it possible for tote return system to be fitted over the top of the pack line-are the totes able to be nested inside each other-reduces the line speed of the return system-power return system to a point, then gravity to start of pack line.
Difficult to advise without seeing system layout.

 

[JTEngTips]

Ross,
Oh, I have layouts and pictures (See Below. I'd like to get the totes from the 'operating' side of the line back to the 'kan-ban' storage area near the asile. Currently, they fall out of the back of the pick line onto the floor.
Respectfully,
Jim

 

[Ross0684]

Jim
From your layout I assume that the system is a "flow thru" storage/order picking system, the shelves/racks being restocked from the "aisle" side, the order picking taking place on the operating side; the empty totes are then discarded back thru the shelves/rack.
I would also assume that you do not want any encumberance on the restock side of the shelve/rack that would impact on the restocking of the storage shelves?
Depending on the vertical height of the shelves at the pick face(multi-levels?), as I previously asked, is it possible to have an empty tote take away over the top of the main conveyor line and then loop around the end of the storage shelf module?
If access to the replenishment side of the shelve/rack is a requirement, can this return line be inclined up and over(using the depth of the shelving/rack) to allow access, then decline down to a discharge point.
Alternatively, have a powered conveyor take away behind the shelving to collect the empty totes and then to track around to a desired discharge point.
As nearly happens in all conveyor layout scenarios, there is always so many "cannot do" answers, but at the end of the day, some sacrifices may have to be made, these to be balanced against a better(more efficient) total operation.
Ross

 

[JTEngTips]

Good. Yes, our pick faces are multilevel. The 'tote return' is on the top, and yes, we don't want the totes at the 'feed' side of the flow through's. So, from your discussion, 'up and over' makes the most sense in my layout. So, who best to contact for quotes, etc? I have 3 different 'return holes' for different size totes, so we'd like to keep it resonable. As the drawing indicates, the totes now are pushed back and now fall on the floor.
Is anyone stacking the totes when they get to the 'other side'. I'm not really familar with what is available.
The operators have taken it on themselves to stack some of them and pull them out on the 'out' side of the line. This is unacceptable to mangement and it's a long way from where they're needed.

 

[Ross0684]

Jim
Re recommendation of suppliers:
Depends on where you are situated; I would suggest that you just do a google search and/or get access to some trade journal publications.
Good luck
Ross