Warehousing Operations Guide: Part 4

(5-C). Order Picking Systems

In warehousing operations, there are three kinds of "Order Picking Systems".

This includes

1. Pick to Cart
2. Pick to Tote
3. Pick to Carton

This article is divided into different parts.

For Part 1 — Click?HERE.

For Part 2 — Click?HERE.

For Part 3 — Click?HERE.

For Part 5 — Click?HERE.

For Part 6 — Click?HERE.

For Part 7 — Click?HERE.

QUICK RECAP

In our previous article, we learned about the different kinds of Picking Processes (Order Picking Methods) that are used in warehousing.

This includes:

1 — Single Order Picking (Discrete Picking)

2 — Batch Picking

3 — Zone Picking (Pick and Pass)

4 — Cluster Picking

5 — Wave Picking

(5-C1) Pick to Cart

In this method, pickers use carts/trolleys that have multiple bins (boxes) to pick multiple orders at once.

The number of boxes can be anywhere from 5 up to 40 or more, depending on the size of the cart/trolley.

Warehouses could be using old manual paper-based picking

OR

They could be using wireless & paperless (automated) technologies, such as:

→ RF Scanners

→ Voice Picking

→ Pick-by Light

This method can be combined with zone and wave picking.

HOW DOES THIS WORK?

→ Pickers pick multiple items (SKUs) for multiple orders using voice picking or pick to light technology.

They are guided by the RF/Voice unit to pick locations.

→ Once the items are picked, they confirm the quantities & pick locations, then they're placed into boxes.

Some warehouses combine Pick-to-cart with packing.

Here is how it works in real life

Items are picked and put directly into shipping boxes, packed and sorted, ready for shipping. All this happens in a single process.

This eliminates time-consuming activities (packing, sorting, and consolidation).

The picking process becomes quicker, reducing shipping times for your customer’s orders. This method is ideal for eCommerce businesses that deal with low volume, small to medium-sized items such as 2-4 items per order.

Benefits of Pick-to-Cart System

? Minimises walking distance

? Reduces picking errors and improves order accuracy

? Reduces picking times

? Increases productivity and order efficiency

? Ergonomics for pickers, resulting in improved safety and wellbeing

? Being wireless/paperless pickers are free to focus on picking. This is handy if the items are large in size

Like any other picking method, this too comes with its own set of challenges which should be considered by the business before implementing it.

(5-C2) Pick to Tote

Designed to accelerate the picking of slow-moving products, this method enables you to pick directly into containers/totes.

There are two ways this system works.

(1) Picker picks using totes on a conveyor belt by going to the pick locations

(2) Goods are brought to the pickers (using a Goods-to-person picking setup)

In the second type, as goods are brought to the picker it helps in eliminating travel time. This increases the efficiency & productivity of the order picking process.

The increase in productivity and reduction in picking times, helps your business save a lot of money.

Considering that picking is the most labour-intensive task accounting for 40-65% of operational costs.

In most cases, two people are working under this system. A dedicated picker and a packer.

? When the picker completes the picking, it is sent to the packing station.

? The packer pack the orders, label them, & attach the invoices so they are ready for shipping.

Watch the video for demonstration

(5-C3) Pick to Carton

In this method, WEIGHT, SIZE and DIMENSION of the order items are taken into consideration to choose the right kind of shipping carton before the order picking even begins.

A specialised software analyses the Size, Weight and Dimension of the order items, that needs to be picked and then directs the picker towards the appropriate box.

Once the boxes are selected, the software prints out the shipping labels which are then placed on the box.

The pickers use a trolley/cart where several cartons (each for a separate order) are placed on it.

All of this is done before a single order is picked.

→ This eliminates the need for a packing station.

→ Cartons can range anywhere from 5 all the way up to 20.

This process is done using specialised software that analyses the necessary data, such as:

→?Dimension: Height, Length and Width of the items

→?Weight of the items

→?Packaging requirements include handling instructions such as fragile items, handle with care, hazardous items etc

The software system will also ask you for additional data input such as:

→ Dimension of empty cartons

→ Weight of the empty cartons

→ The maximum load capacity of each carton

→ Any other additional or necessary information required by the software for the cartonization

which are taken into consideration to calculate and provide you with the ideal/suggested carton size for each order, making the process of pick and packing very efficient.

BENEFITS OF USING THIS SYSTEM

→ Helps you save on many costs

→ Optimised labour usage

→ Reduced handling

→ Optimised picking, packing and shipping processes

→ Faster deliveries to your customers

→ Reducing shipping costs

→ Improved customer service

→ Improved order accuracy

→ More picks per hour per picker

→ Reduced material and packaging costs

This article is divided into different parts.

For Part 1 — Click?HERE.

For Part 2 — Click?HERE.

For Part 3 — Click?HERE.

For Part 5 — Click?HERE.

For Part 6 — Click?HERE.

For Part 7 — Click?HERE.

Published on 11/11/2021

Last Updated: 02/12/2021 at 12:47 AM