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Goods handling in the warehouse is one of the central elements of the supply chain: Order picking may be the most resource-intensive regarding time and personnel efforts. The right choice depends on your business, your operations structure and your processes to maximize efficiency.
We have gathered insights on the different picking methods for you, helping you find the right one for your warehouse. You will find insights on advantages and disadvantages as well as some tips on how to chose the right picking method.
© Picavi at Ecomal
Picking is a process for the provision of goods. A common example from eCommerce is the compiling of different goods ordered for delivery to the Customer.
The most common method is manual picking: this involves warehouse staff picking the correct quantities of items in the order from the various storage locations and putting them together for dispatch.
The main goals of order picking are short picking time and high picking quality to keep costs low in the supply chain.
Some logistics companies rely on automated systems such as picking robots or picking machines for the provision of goods, but these require high investment volumes and structural changes to the warehouse.
There are two main categories of order picking:
Pick-by-paper is a classic process for order-based picking, but it cannot keep up with today’s demands. It is extremely susceptible to errors, especially with high pick densities. The technology breaks in the process also make it virtually impossible to track errors. Given the vital importance of efficiency in warehouses, it is no longer fit for purpose.
In pick-by-scan, the information on the picking list is presented to the picker digitally on a mobile handheld scanner. This device is connected to the higher-level order picking system.
Pick-by-light is best suited for use in warehouses with high throughput and large item quantities. This system guides the picker through the warehouse using light signals that are attached to the shelves in displays and buttons. Once they reach the storage space, the picker confirms their action, i.e. removing goods or filling the storage space in a so-called put-to-light process.
Pick-by-voice is a popular picking method in logistics. The picker receives the order information directly to their ear. Using a headset and microphone, the picker is guided through the warehouse to the items by a computer-generated voice and communicates directly with the higher-level system.
Pick-by-vision is based on the fact that 80% of the information presented to us every day is taken in and processed visually. Picking with smart glasses allows pickers to be guided visually through the warehouse and the entire picking process. The system combines the benefits of pick-by-voice and pick-by-light, and is both highly flexible and adjustable. A barcode scanner integrated in the smart glasses makes picking easier and less tiring. All of the relevant information is displayed in real time on the glasses. This increases reliability and allows the picker to check storage locations, items or item numbers at any time. The compulsory scanning verifies that the correct item has been picked. The picker has their hands free at all times and receives a confirmation once they have successfully processed the order.
Choosing the right picking method is crucial for the efficiency of your warehouse. Find the Pros and Cons of the different methods below:
Each of these methods has advantages and disadvantages that you need to consider for your use case.
The higher the turnover, the more interesting new picking methods might be. Their implementation can reduce costs in the long term: higher picking speeds and a significantly reduced error rate make processes more efficient, and high ergonomics increase employee satisfaction. Especially with bulky or heavy items, the hands-free works best.
Modern systems integrate these advantages and enable flexible use. Systems such as Pick-by-Vision can be flexibly expanded and can be used in different areas of application, e.g. for inventory or incoming goods inspection.
Investment costs
You should always find out about the expected investment costs and weigh these up against the expected ROI.
Throughput
Make sure to consider the order capacity to be processed when making your decision. How many orders do you process per day and per time unit in your warehouse?
Warehouse size
Consider the amount of space used in your warehouse. Take into account criteria such as the width of the aisles, the height of the shelves and the available levels.
IT compatibility
Check whether the new order picking technology is compatible with your existing warehouse IT infrastructure.
Staff
Get your staff involved in the process. What are the needs of your pickers? Decide which system addresses these needs best and customize it to your team.
Order picking is one of the most time and work-intensive tasks in the warehouse. As the last link in the internal logistics chain, it has a direct impact on customer satisfaction and therefore the company’s reputation. Any errors in order picking are felt by the customer immediately. Many companies are exploring automated options for this process. But the overwhelming majority, around 80%, still rely on more flexible manual solutions. As product portfolios continue to grow and become ever more diverse, and delivery times become ever shorter, this flexibility can be a crucial advantage.
The best user interface belongs to pick-by-vision. It relieves the mental load on the picker by reducing the amount of information displayed to a minimum. Pick-by-vision guides the worker precisely through the process and makes their job easier. This significantly reduces the mental and cognitive load on the picker. The user interface can be easily adapted to the individual needs of the worker at any time.