How does an A-frame work? How to manage up to 4,000 orders per hour

Productivity and efficiency are fundamental for the success of any business. In logistics, it’s no different, especially when it comes to picking, a process considered the “heart” of a warehouse. Speed and accuracy are determining factors not only to ensure customer satisfaction but also to reduce operational costs. That’s why logistics managers are increasingly investing in exclusive technologies for picking. With innovations, many companies are already able to deliver on the same day (same-day delivery) or the next day (next-day delivery), gaining a significant competitive advantage.

One of these technologies widely used in large logistics warehouses is the A-Frame, a high-productivity system that allows for the separation of hundreds of orders in a short period of time, with high accuracy and reduced labor. It is estimated that the A-Frame increases the separation speed by up to 80%, while drastically reducing the occurrence of errors.

What is the A-Frame?

The A-Frame consists of a modular system, integrated with a conveyor belt on which a structure composed of a series of channels covers both sides. Each channel works with a specific SKU, having the capacity to store multiple units. The conveyor belt is responsible for “receiving” the items and bringing them to the departure areas.

The nomenclature A-Frame is due to the fact that, when viewed from the front, the equipment has a shape similar to the uppercase letter “A”.

How does A-Frame work?

As mentioned earlier, each A-Frame channel stores an SKU. When the order is sent to the machine, usually through integration with a WMS system, the requested products are ejected through the channels and fall onto the conveyor, with each section associated with a particular order. The selected items are then transported to the end of the A-frame and deposited in a bag or suitcase. Subsequently, the orders are transported to a packaging station where they are checked, packed, labeled, and then transported directly for shipping.

The A-Frame modules can be used either in series or in parallel to increase the system’s capacity. Additionally, the automation can work integrated with other separation systems. During operation, the A-frame can decelerate or accelerate automatically based on the needs to adapt to the distribution of items. To give an idea of its efficiency, it is capable of picking from 250 to 4,000 orders per hour. Despite the high productivity, the equipment has constraints related to the fragility and/or format of the moved products.

It is also important to add that, to achieve maximum efficiency, the replacement of products in the system lines must be quick and decisive, avoiding any channel from emptying. To do this, it is customary to connect a flow rack line on the side of the A-frame with operators dedicated to channel replenishment. Another solution found by companies for cases of orders requiring a large quantity of the same SKU is to insert an SKU in more than one channel.

Operations where it is most used

In general, the A-Frame is used in operations that work with small objects and similar packages. The system is widely used in pharmaceutical and cosmetic logistics, but it can also bring advantages to other types of companies, such as those working with tobacco, small office supplies, or contact lenses, for example.

What are the advantages of A-Frame?

The A-Frame system provides a series of advantages to the operation, among which we can mention:

– High productivity: A-Frame distributors are capable of ejecting up to 5 items per second, per channel;
– High productivity and accuracy, even during peak periods;
– Better use of labor: with the automation of picking, it is possible to redirect employees to other important activities at the DC. Generally, only one employee is needed to work on channel replenishment, which also means a reduction in labor costs;
– Efficient use of storage space;
– Reduction of errors;
– Easy integration with other systems;
– Possibility of expansion due to its modular structure.

So, if you need high yield in picking, combined with a reduction in labor costs, A-Frame can be the ideal solution for your warehouse if you work with stackable products in the channels. By separating faster, you will be able to deliver quickly and even increase your sales. Therefore, A-Frame tends to have a high ROI, especially if integrated with other systems that bring greater efficiency to the operation.

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