Order Picker Attachments: Carts, Platforms, and Fork Compatibility

Order picking is the most labor-intensive process in the modern warehouse. That’s not hyperbole: By one estimate, order picking accounts for 50% to 75% of total operating costs and roughly 55% of all labor hours.

And as the average industrial footprint continues to grow, the distance selectors must travel has increased significantly. To maintain throughput, facility managers need the right material handling equipment.

If you’re outfitting, here’s how to find order picker attachments that make sense for your operation.

Differentiating Order Picker Attachments

We can organize order picker fork attachments into four general categories: Cart, Platform, Standard, and Furniture. Note that this is our terminology — it’s not an industry standard — but it’s a simple way to classify order picker accessories by design and function.

All of these attachments integrate with Class II industrial trucks, but they serve different roles in the fulfillment process:

• Cart: These are freestanding units equipped with heavy-duty casters and integrated fork pockets. Models like the BHS Modular Order Picker Cart  (OPCM) function as mobile workstations that can be positioned manually on the floor or secured to a truck for elevated picking.
• Platform: Platforms are caster-less, deck-style attachments designed to provide a stable work surface for picking directly to pallets or large bins. The Modular Order Picker Platform  (OPPM) prioritizes a large, open footprint for bulkier items or high-volume case picking.
• Standard: These attachments are designed for use with traditional order picker trucks; they utilize standard fork lengths ranging from 42 to 48 inches.
• Furniture: These are attachments engineered for specialized furniture order picker trucks. Furniture order pickers have extended fork lengths — up to 96 inches — to support oversized loads. BHS Order Picker Furniture Carts  and Order Picker Furniture Platforms  fall into this category.

Any attachment that elevates personnel must comply with the OSHA Powered Industrial Truck Standard (29 CFR 1910.178) and ANSI standards such as the ANSI/ITSDF B56.1 safety standard.

Related: Pick, Pack, and Ship: Warehouse Optimization Strategies

Truck Compatibility: Order Picker vs. Furniture Picker

The compatibility of an attachment largely boils down to fork length and fork pocket placement. 
A standard order picker is designed to maneuver in narrow aisles with a compact load. A furniture picker's longer forks provide greater leverage and stability.

Using a standard platform on a furniture picker (or vice versa) isn’t advisable: If the fork pockets are not deep enough to accommodate long furniture forks, the attachment may shift during travel. Likewise, long furniture forks extending past the front of a standard cart can create a striking hazard in tight aisles.

Modular designs from BHS address this by allowing for custom fork pocket configurations to match specific fleet requirements.

Advantages of Modular Construction

BHS utilizes modular construction for the Order Picker Cart family for a few simple reasons:

• Future-Proof Adaptability: Modular units can be reconfigured in the field. If your product mix changes, features such as removable push handles or adjustable shelves can be modified on the fly.
• Field-Adjustable Specs: Safety features such as steel handrails and anti-skid tape can be added or removed to meet the needs of the workflow.
• Accelerated Lead Times: Because modular components are standardized, we can design, build, and ship custom-configured units significantly faster than manufacturers who rely on fabrication alone.

We proudly design and manufacture our modular material handling equipment in the USA — and because we operate our own warehouse, we can provide the tailored guidance that operations need to build safe, efficient facilities.

Related: 5 Ways to Reduce Warehouse Picking Error Rates

Optimize Your Order Picking Strategy Today

The right attachment converts a standard truck into a specialized tool tailored to your specific material flow. If you understand the needs of your operation, BHS can find or engineer a solution that supports the way you work — and if you’re still in the planning stages, we can help you get to the next step.

To discuss order picker attachments for your facility, call the BHS sales team at 1.800.BHS.9500 or request more info online.