Method and apparatus for filling orders in a warehouse

A method of consolidating from all different warehoused sku's different selected ones of said sku's during predetermined short regularly recurring pick periods comprising the steps of:

• classifying warehoused items according to a predetermined sku designation;
• dividing pick areas into two sets of pick faces;
• determining by sku designation all of the different items needed for all orders to be picked during an individual subsequent pick period;
• determining the individual total number of each of the different needed items according to their sku designation, and determining in descending order the sku's with the highest total number needed to be picked for all orders during such subsequent pick period;
• assigning and stocking the sku's with the greatest total number needed to be picked during such subsequent pick period into a first set of primary pick faces having a maximum number of pick faces corresponding in number to less than approximately 50% of all different sku's warehoused, with each pick face containing only one type of item;
• generating pick slips identifying by individual orders the items needed to complete each such order and designating the individual pick faces containing each of such items;
• picking items for an order from the first set of pick faces for items stocked in the first set of pick faces;
• stocking a second set of pick faces, in addition to the first set, with items that are not currently stocked in the primary pick faces;
• picking from the second set of pick faces all items needed for an order that cannot be picked from the first set of primary pick faces;
• re-assigning sku's to and re-stocking the first set of pick faces for the next successive pick period with sku's having the greatest total number needed to be picked during such next successive pick period.