Warehousing Operations Guide: Part 3

(5-B). Order Picking Processes

This is also known as Order Picking Methods.

This article is divided into different parts.

For Part 1 — Click?HERE.

For Part 2 — Click?HERE.

For Part 4 — 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 six (6) different kinds of picking technologies used in warehousing operations.

This includes:

1. Pick-by Voice
2. Pick-by Light
3. Pick-by Radio Frequency (RF)
4. Pick-by Paper
5. Pick-by Vision
6. Pick-by Robots

Now, we will learn about the different Picking Processes (Order Picking Methods) that are used in warehousing.

This includes

(5-B1) ? Single Order Picking (Discrete Picking)

(5-B2) ? Batch Picking

(5-B3) ? Zone Picking (Pick and Pass)

(5-B4) ? Cluster Picking

(5-B5) ? Wave Picking

(5-B6) ? Advanced Systems Picking

(5-B1) ? Single Order Picking (Discrete Picking)

This type is commonly used due it its simplicity and ease.

Therefore, it is ideal for paper-based picking, providing faster order fulfilment for your warehouse.

It comes with a few drawbacks, though.

1) Inefficiency and Travel Time

It is inefficient, and the travel time required to pick orders is quite significant compared to other picking methods.

2) Optimisation, Accuracy and Costs

The order/sequence in which items are picked and found in pick locations is not optimised

This has a knock-on effect on the speed and accuracy of order fulfilments.

This leads to the waste of

→?Time

→?Money

→?Resources

An alternative is to use a Warehouse management system (WMS)?to help increase the efficiency and productivity of the warehouse.

A business must carefully select the right type of WMS before implementing it. Otherwise, all the efforts would be for nothing.

Now, that we know the pros and cons of "Single Order Picking"

HOW DOES IT WORK?

In this type of PICKING - Warehouse order pickers pick one order at one line at a time.

They travel around the warehouse to find each item on the "Picking List" and complete the orders, one order at one line item at a time.

Then they take the picked order items to the packing station, where they are packed and taken to the assembly area for despatch.

(5-B2) ? Batch Picking

In Batch Picking, pickers pick multiple orders (batches) at the same time, picking one Stock Keeping Unit (SKU) at a time.

A picker picks multiple SKUs (same type) for multiple orders.

Example:

Instead of picking one item (One SKU - Let's say a can of beans).

You pick 9 for 3 different orders.

> 2 for Order A

> 3 for Order B

> 4 for Order C

After picking, they are taken to the sorting station and organised into different orders delivery.

Some warehouses use trolleys and carts that will have different compartments and are used to fulfil multiple orders.

Making sortation easy, & speeding the process of picking & packing.

All of this helps in eliminating unnecessary travel trips to the same area of a warehouse, speeding up the order fulfilment operations.

This means

> Faster Deliveries

> Increased speed to market

> Shorter storage times

> Optimised pickings

> Cost savings ($$)

It can work both with "manual & automated" picking systems.

?? In Manual Picking

It allows the pickers to pick SKUs for multiple orders at a time when they go to the pick locations in the warehouse.

?? In Automated picking

A picker stays in a single location, while Horizontal and Vertical carousels deliver the SKUs to the picker.

Some of the benefits of this method are:

— Reduced travel time

— Increased productivity

—?Increased efficiency

(5-B3) ? Zone Picking (AKA - Pick and Pass)

As is evident from the name, in this kind of picking a warehouse is divided into different zones (areas), which contains different SKUs.

A warehouse Manager assigns different pickers to each zone.

HOW DOES THIS WORK?

Depending on the Warehouse and Zone Setup

— Totes/Bins/Cartons

Go through the different zones where each picker picks the order items & puts them into the box. The process is repeated until all the order items have been picked.

Note

— A box could be a carton, tote or a bin

To get the most out of this system, you need

— A well-trained warehouse manager

— A good working WMS

— A suitable setup that works well for the operations

Advantages of Zone Picking

— Reduces walking time as workers stay in one zone (section)

— Good for fulfiling larger orders which help speed up delivery times, resulting in happy and satisfied customers

— It is easy to train employees on using it which is cost-saving

— Eliminates travel congestion

Disadvantages of Zone Picking

It also comes with disadvantages like any other system which should be taken into consideration before implementing this system.?

Things such as:

— Order inaccuracies/discrepancies

— Fluctuations in demand

Can create big challenges in your warehousing operations.

NOTES

— Depending on the SKUs stored in a zone, it can have different storage systems and technologies in place

— Each box/carton/bin represents a different order

— There are multiple variations of this method which depends on the size and nature of the business, and zoning set up in the warehouse. In other words, not all zone picking are the same across the industry.

(5-B4) ? Cluster Picking

In this method, pickers work on multiple orders at the same time picking different items (SKUs) for orders.

This is different from “Batch picking” where similar items are picked together for multiple orders.

This is done in two ways

1) Using Vertical Lift Modules (VLM)

2) Using carts/trolleys with multiple containers (boxes/bins/cartons)

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Using carts/trolleys with multiple containers (boxes/bins/cartons)

In this setup, Pickers pick up trolleys with multiple bins

e.g., A trolley/Cart with 18 bins

Then they go through the different aisles of warehouses to collect order items and put them into the bins.

? Each bin represents a sales order.

This is ideal for eCommerce stores that ship small quantities of sales orders.

Advantages

— Cuts travel time by making fewer trips (you don’t have to walk the floor numerous times)

— Increased number of orders picking helps with shipping orders faster to customers and end-users

— Consolidated orders list helps with pick accuracy

Disadvantages

— Needs a sophisticated Warehouse Management System (WMS)

— If clusters are not assigned and scheduled properly, they will not be efficient, resulting in the loss (money $$) and decreased productivity

— The capital ($$) required for maintenance and implementation of the system may be too much for some companies. A cost-benefit analysis should be done by the business before deciding to go ahead with this picking method.

(5-B5) ? Wave Picking

In this method, orders are grouped together and then released in batches.

Pickers then pick them up at specific windows (intervals) throughout the day.

Wave picking requires a Warehouse Management System (WMS) & works with the inventory in your warehouse to create a consolidated picking list for pickers.

How orders are grouped & picked depends on the following criteria:

— Transportation schedules

— Packaging needs

— Labour Requirements (Warehouse staff)

— Shipping deadlines (from customers)

— Carrier deadlines (from your shipping partners such as trucks, railways, ports etc)

— Equipment’s required for picking

— Design and layout of the warehouse

— Customer delivery areas (metro or regional)

— Loading and Unloading times

WMS considers & applies the above-listed criteria to create efficient picking lists for orders to be picked at the right time.

Time reduction is achieved by finding a good workflow based on the warehouse design, order requests, layout of the picking areas & criteria listed above.

This creates efficiency in the picking process which could not be achieved by manual picking.

The process is structured, and these waves are released throughout the day at different intervals to make the most out of

1. Labour
2. Equipment
3. Inventory

and to meet different internal and external deadlines. Optimised picking help reduce picking costs, which are major in running a warehouse.

This is ideal for Warehouses and Distribution Centres (DCS) with a large number of items (Stock Keeping Units - SKUs)

Advantages

—?Better use of labour and transport schedules

— Accuracy in order picking helps reduce return orders which also reduces the costs associated with return deliveries

— Helps with improving operations efficiency

— Fast and accurate order deliveries mean “Happy Customers” which will bring more business to your company

Disadvantages

— Requires a solid WMS to work with, otherwise, you won't achieve the benefits

— Without a well-trained manager, it won't work well

— Inaccurate information can have a big impact on the picking process if it is not addressed immediately on time

(5-B6) ? Advanced Systems Picking

In this method, the warehouse uses a variety of picking methods that we previously discussed which are:

— Single Order Picking

— Batch Picking

— Zone Picking

— Cluster Picking

— Wave Picking

This means a warehouse can be using a combination of the above methods to meet its daily targets, improve delivery timeframes, cope up with seasonal or promotional demands.

e.g., they could be using Batch, Zone & Cluster picking at the same time in different parts of the warehouse.

Warehouse layout, setup, zones & storage optimisation is very important in this method.

The warehouse could also be using "Automated Storage Systems" such as:

— Vertical Lift Modules (VLM)

— Horizontal Carousels

Which not only improves space utilisation but also speeds the process of order picking.

This helps in reducing shipping (delivery) times which helps improve your customer service while also reducing operational and storage costs.

On top of that, they could be using several automated picking technologies such as:

— Voice picking

— Vision Picking

— Pick to light

— Robot-assisted picking

to improve their operations & meet their warehousing demands/needs.

This article is divided into different parts.

For Part 1 — Click?HERE.

For Part 2 — Click?HERE.

For Part 4 — Click?HERE.

For Part 5 — Click?HERE.

For Part 6 — Click?HERE.

For Part 7 — Click?HERE.

Published on 10th November 2021.

Last Updated: 02/12/2021?at?12:45 AM.