Picking. solutions for warehouses
Picking is often the most labor-intensive part of the logistics chain, responsible for as much as 50% of the total operating costs in a warehouse.
Picking is often the most labor-intensive part of the logistics chain, responsible for as much as 50% of the total operating costs in a warehouse.
While consumers increasingly expect orders to be delivered within a few hours, warehouse employees sometimes have to collect thousands of items per day with 100% accuracy. This scale of volume, as well as the required precision, makes the process so vulnerable.
The most common problems are human error, inefficient aisles, and a lack of real-time visibility. Picking errors lead not only to costly returns but also to dissatisfied customers. Additionally, the workflow is often slow due to ‘wandering time’: employees walk long distances through the warehouse to find items that are arranged randomly or are outdated.
Picking is often the most labor-intensive part of the logistics chain, responsible for as much as 50% of the total operating costs in a warehouse.
While consumers increasingly expect orders to be delivered within a few hours, warehouse employees sometimes have to collect thousands of items per day with 100% accuracy. This scale of volume, as well as the required precision, makes the process so vulnerable.
The most common problems are human error, inefficient aisles, and a lack of real-time visibility. Picking errors lead not only to costly returns but also to dissatisfied customers. Additionally, the workflow is often slow due to ‘wandering time’: employees walk long distances through the warehouse to find items that are arranged randomly or are outdated.
To solve these bottlenecks, companies are turning to technological transformation. One of the most effective methods is the use of Voice Picking or Pick-to-Light systems. These technologies guide employees directly to the correct location via voice commands or light signals, keeping hands free and drastically reducing error margins.
Voice Picking
With Voice Picking, the warehouse worker receives instructions from the Warehouse Management System (WMS) via a wireless headset. Instead of looking at a list on a small screen or papers, the picker listens to instructions such as “Go to location A12, picked 3 pieces of product X”.
After performing the task, the employee speaks a verification code (for example, a barcode series or a specific keyword). The system immediately confirms whether the action has been performed correctly. If an error is made, the user receives immediate feedback. This ensures that the eyes and hands are completely free for lifting and moving goods, which increases safety and speed. It is ideally suited for warehouses with a high daily volume and lighter, smaller items.
With Pick-to-Light systems, small light modules are mounted on the shelves or racks where the items are located. When an order arrives, the lights at the correct location light up (often bright red or green) and display the quantity of items to be picked on a small screen.
The employee simply walks along the rows, sees where to pick thanks to the flashing light, takes the products, and presses a button on the module to confirm the signal. This system is very visually intuitive and requires no training in complex software. It is ideal for high-speed picking in environments with many small parts (such as e-commerce or pharmaceutical products), where speed and precision are crucial.
Lean lifts or part towers.
A third solution is the use of lean lifts or part towers. This is a vertical storage system. Limited to a paternoster. With a lean lift, the drawers are located at the front and back, and the drawers in the middle are moved. This provides more flexibility and speed in presenting drawers to the picker.
These lifts have their own inventory management system that, in almost all cases, communicates with an ERP or WMS system. The lift receives its orders from these systems, including both picking and putaway orders.
The employee remains standing by the lift and starts the orders. The lift presents the drawers containing the items to be picked [or putaway] to the employee. The storage position is often indicated by an LED light.
These lifts offer significant storage capacity, and not just for small, lighter goods. Drawers have load capacities of up to 500 kg. Additionally, significant time savings are achieved because items are brought to the employees.
WMS systems
An additional solution involves the application of dynamic route optimization. Instead of static plans, the software calculates the shortest route for each order, leading to substantial time savings. Furthermore, the use of autonomous mobile robots (AMRs) is being utilized. These robots bring the items to the picker.
Data
Data and data analysis always play a crucial role. Not least, the data must be reliable and relevant. Too often, article files are corrupted, not up to date, or unusable due to poor article strategy. This leads to workarounds on the shop floor just to pick and ship an item(s) anyway. Poor data is a hidden but major cause of many errors and inefficient processes.
With reliable data and by using historical records, warehouses can position their assortment more strategically. [ABC methodologies, for example] In combination with automated equipment, this forms the key to a future-proof warehouse, where speed and precision go hand in hand.
sources:
https://addvise.net/order-picking-methodes-voor-uw-warehouse/
