Introduction

Another day, another mountain of picks. Are you prepared to handle the order volume? What if something goes wrong? Will it put you in a delay cycle that you won’t be able to get out of?

The answer to these questions lies in understanding what order picking solutions are available, weighing their advantages against their disadvantages and identifying the right one for your specific situation, challenges, and goals.

In this blog post, we explore the topic of order picking. We will identify what it is, the different kinds of picking methods, if it’s a challenging task, and finally, we’ll share some tips for boosting order picking efficiency.

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What is Order Picking?

Order picking involves selecting and gathering products in a warehouse as per the specific orders of customers. It is typically the most labor-intensive and costly activity for almost every warehouse. The accuracy and efficiency of picking processes significantly affect the speed of delivery and the condition in which goods arrive at their destination, influencing customer satisfaction and retention.

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Kinds of Order Picking

Order picking methods can greatly vary in complexity and technology used, depending on the specific needs and strategies of your warehouse. Here's a deeper look into the various types of order picking systems:

Manual Order Picking

This is the most basic form of order picking, involving workers manually collecting items from their storage locations based on individual order lists. This method is highly dependent on human labor and decision-making.

Advantages:

• Flexibility in handling a wide variety of products.
• Low initial investment as it requires minimal technology.

Disadvantages:

• Labor-intensive and can be slow.
• Prone to human errors leading to incorrect picks and returns.

Semi-Automated Order Picking

Semi-automated order picking is often a go-to approach because of its relative cost-effectiveness, efficiency, and reduced errors. A common semi-automated order picking system is pick-to-light. Pick-to-light systems enhance the manual picking process by using lights and digital displays to guide pickers to the correct locations and quantities of items needed for each order.

Advantages:

• Reduces picking errors by clearly indicating where and what to pick.
• Increases picking speed compared to purely manual methods.

Disadvantages:

• Requires investment in digital systems and infrastructure.
• Still relies on human pickers, retaining some manual process inefficiencies.

Automated Order Picking

Automated Storage and Retrieval Systems (ASRS) represent the higher end of technology use in order picking. These systems use robotic elements and conveyors to automatically retrieve items without direct human interaction.

Advantages:

• Maximizes efficiency and accuracy, dramatically reducing picking errors.
• Saves significant time in large operations and reduces labor costs.

Disadvantages:

• Higher upfront costs due to the need for sophisticated technology and installation.
• May require ongoing maintenance and updates.

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Download Now: Best Practices For Order Profiling

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Additional Types of Order Picking Systems

Each of these picking methods has its own set of strengths and weaknesses. Therefore, warehouses will often use a combination of these systems to optimize their operations. This approach allows them to tailor their picking strategy to their specific order profiles, product types, and operational goals. By Integrating the right mix of these strategies, warehouses can significantly enhance the efficiency and accuracy of their order fulfillment processes.

Voice Picking: Workers use headsets that voice instructions for picking tasks, allowing hands-free operation, and reducing error by confirming picks verbally.

Mobile Scanner-Based Picking: Utilizes mobile devices that guide pickers through the warehouse and confirm picks via scanning, enhancing accuracy and efficiency.

Zone Picking: The warehouse is divided into different zones, and pickers are assigned to specific areas, reducing travel time and potentially increasing specialization in product types.

Wave Picking: Similar to zone picking but involves organizing picking activities into waves throughout the day to maximize efficiency based on factors like shipping schedules or order priorities.

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Is Order Picking Difficult?

Order picking can be challenging due to several factors:

• Volume of Orders: High order volumes can overwhelm manual picking systems.
• Variability of Items: Different sizes, weights, and storage needs complicate the picking process.
• Accuracy Requirements: High accuracy is crucial, as mistakes lead to returns, dissatisfied customers, and increased costs.

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Tips To Improve Order Picking Efficiency

Improving order picking efficiency involves several strategies:

• Optimization of Picking Paths: Reducing travel time between picks through better warehouse layout and item organization.
• Technology Integration: Implementing systems like barcode scanners, voice-directed picking, and robotics.
• Worker Training and Ergonomics: Ensuring that pickers are well-trained and that picking tasks are designed to minimize physical strain.

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Conclusion

At the end of the day, effective order picking is vital for the success of your warehouse operations but it’s a constant dance between planning, problem solving, and supporting your team to make those “Add-To-Cart” clicks a reality. Through strategic improvements and integration of technology, your business can achieve faster, more accurate order picking, which in turn enhances your competitive edge in the market.

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Prior to moving forward with any picking technologies, your processes should first be analyzed and optimized. We can help lay the groundwork for a successful implementation by using Raymond Lean Management (RLM) to assess different aspects of your operation. Whether it’s through faster fulfillment or reduced errors, our certified professionals will ensure you get the most out of your resources.