Warehouse picking processes are often focussed on order picking, simply because this is an extremely intensive area within warehouses and it can account for significant costs. So it is imperative that any warehouse picking processes that you use are as efficient as possible and you need to seek to improve these processes wherever possible.
One of the key ways to improve warehouse picking processes is to automate them as much as possible. Some warehouses are actually completely ‘people free’ and they are fully automated with both pallets and products being transported on a system of conveyor belts, cranes or automated storage systems. These are controlled by logistics and the whole process requires very little in terms of human input. Obviously this keeps the staffing costs low, but on the other hand the set up costs are quite significant and there can be enormous problems if the system fails; so there are some inbuilt risks with a purely automated system. However, automating the system as much as possible can certainly help to ensure that the costs of warehouse picking processes is kept low.
Slotting within the warehouse is obviously important, because the slotting determines where an item is picked from whether that be a carton flow or a pallet rack. So careful consideration has to be given to the physical positioning A careful slotting plan needs to be developed to enable the warehouse to function effectively and to improve its ability to rotate stock efficiently.
The other main system for picking items is the ‘pick to light’ system (see here http://www.workingmachines.com/ and http://www.prlog.org/10782210-lightning-pick-and-the-role-of-pick-to-light.html for more information and examples) that uses a bar code which is scanned (the label is on the box). Then a digital display that is located in the area in front of the ‘pick bin’ will give the operator all the information that they need, for example, how many of something that they need and so on. Often the pick to light system will be used for up to 20% of their best selling products.
The traditional pick ticket systems that used to be used are very prone to error and as such are regarded as being quite inaccurate, so the VRS or pick to light systems are seen as better ways to bring improvements to the picking processes.
Often companies find that it can be beneficial to have items that are the most frequently ‘picked’ close to areas from where they are dispatched. So if they are to be shipped then they should be located close to the shipping area; if they are frequently picked to be transported by road, then they should be located nearest to the road distribution point. This saves time in terms of how long it takes to pick the item. However using this kind of system requires constant monitoring of sales information to make sure that there has not been a change in terms of sales and that those items are still the most frequently picked.
The layout of the warehouse is also of critical importance. A good warehouse will only have a very short travel distance between different locations which means that productivity for tasks like picking and stock cycle counting can be greatly improved. The downside to this is that it takes a lot of monitoring to check that items are the ones that are often picked ‘together’ since demand will fluctuate at certain points within the year.