How can you optimize your zone picking strategy?

1 Assess your warehouse layout

The first step to optimize your zone picking strategy is to assess your warehouse layout and determine how to divide it into zones. Ideally, you want to create zones that are logical, manageable, and consistent. You can use various criteria to define your zones, such as product type, size, weight, demand, or location. You should also consider the flow of goods, the accessibility of storage locations, and the proximity of packing and shipping areas. By creating optimal zones, you can reduce the distance and time that pickers need to travel, as well as the risk of errors and congestion.

2 Assign your pickers to zones

The next step is to assign your pickers to zones and define their roles and responsibilities. Depending on the size and complexity of your warehouse, you can use different methods to assign your pickers, such as fixed, floating, or rotating. Fixed pickers stay in one zone and pick only the items from that zone. Floating pickers move between zones as needed and pick items from any zone. Rotating pickers switch zones periodically and pick items from different zones. You should choose the method that best suits your warehouse operations, taking into account the skill level, availability, and preference of your pickers.

3 Implement a zone routing system

The third step is to implement a zone routing system that guides your pickers through the picking process and ensures that orders are completed efficiently and accurately. A zone routing system can be either sequential or parallel. Sequential routing means that orders are passed from one zone to another in a predetermined sequence, and each picker picks only the items from their zone. Parallel routing means that orders are picked simultaneously in multiple zones, and each picker picks all the items from their zone. You should use the routing system that best matches your order volume, complexity, and priority.

4 Use technology to support your zone picking

The fourth step is to use technology to support your zone picking strategy and enhance your performance and quality. Technology can help you automate, streamline, and optimize various aspects of your zone picking process, such as inventory management, order processing, picking instructions, verification, tracking, and communication. You can use various tools and devices to support your zone picking, such as barcode scanners, RFID tags, voice picking systems, mobile computers, or warehouse management systems. By using technology, you can reduce errors, increase speed, and improve visibility and control.

5 Monitor and evaluate your zone picking performance

The fifth step is to monitor and evaluate your zone picking performance and identify areas for improvement. You should track and measure various indicators of your zone picking performance, such as pick rate, accuracy, cycle time, productivity, or customer satisfaction. You should also collect and analyze feedback from your pickers, customers, and managers. By monitoring and evaluating your zone picking performance, you can identify the strengths and weaknesses of your zone picking strategy, and make adjustments and improvements as needed.

6 Train and motivate your pickers

The sixth and final step is to train and motivate your pickers and ensure that they are competent, confident, and committed to your zone picking strategy. You should provide your pickers with adequate training and guidance on how to use your zone picking system, technology, and procedures. You should also motivate your pickers by setting clear and realistic goals, providing feedback and recognition, offering incentives and rewards, or creating a positive and supportive work environment. By training and motivating your pickers, you can increase their engagement, satisfaction, and retention, and ultimately optimize your zone picking strategy.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?