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dg2n / Fulfilment & dark stores

Follow the order through the whole facility.

Review the path from order picking to packing and handoff.

Explore the decisions

For fulfilment, dark store, and operations planning teams

From pick zones to order handoffIllustrative fulfilment plan: two picking zones feed a consolidation point, packing stations, and a handoff area. Review work allocation and the queues between tasks.Pick zone APick zone BConsolidate& reviewPackHandoffReview order flow across tasks and handoffs
From pick zones to order handoff · Illustrative plan

Illustrative scenario / The order does not stop at picking

Follow the work through every handoff.

One space. A decision worth exploring.
01

The current arrangement

Orders from different pick zones arrive at consolidation together. The queue takes up space the packing team also needs.

02

The alternative

Explore a different consolidation position or release pattern. Follow the same order mix through picking, packing, and handoff.

03

The team’s decision

Review workspace, staffing, and task assumptions together. Compare the pilot with the current operation across the whole order journey.

A wider view of the possibilities

Connect the work between the stations.

01

Balance work across zones

Does the order mix put uneven pressure on your picking areas?

Review order activity by location and category. Compare how picking arrangements and work allocation could change the load on each zone.

02

Review the packing handoff

What happens when picked orders arrive at packing together?

Map the transition from pick completion to consolidation and packing. Evaluate the workspace and task assumptions that could explain queues or repeated handling.

03

Plan for a different demand pattern

How would the same facility handle a different order mix?

Define a representative demand scenario and review picking, replenishment, and packing together. Keep staffing and processing assumptions visible when comparing options.

From the actual to the possible

Start with your space.
See what could change.

Explore how order mix, work allocation, and facility layout affect the way your fulfilment team works.

Prepare your first facility →
The working layout
Pick, pack, consolidation, and handoff zones; storage locations; fixture dimensions; and reference photos.
Order and stock records
Item and inventory exports, timestamped order and pick records, and available replenishment or packing activity.
The workflow
Batching rules, zone assignments, staffing context, and the task sequence from order release to handoff.

A clear path to a real-world decision

See it together.
Move forward together.

  1. 01

    Trace a representative order

    Review the facility and data with the team. Map the tasks and handoffs that connect picking, consolidation, and packing.

  2. 02

    Define a comparable scenario

    Choose a question about allocation, workspace, or demand. Document order mix, task timings, and staffing assumptions for both alternatives.

  3. 03

    Review before changing the shift

    Check the proposed arrangement with facility owners. Use a limited trial to measure the effect on order flow and the downstream handoff.

Modelled outcomes depend on source data and assumptions. Review proposals with the people responsible for the space and validate selected changes against observed results.

Your space. Your next possibility.

Bring your next fulfilment challenge.

Share a facility layout and a question about picking, work allocation, or packing. We will discuss how to structure a useful comparison for your team.

Book a demo