Page 17 - Logistics News - July August 2023

P I CKIN G

rder picking is one of the most labour-intensive picking involves workers picking multiple orders at the
processes in the warehouse. In fact, labour accounts same time, with the orders grouped by SKU type. This
Ofor nearly 65 percent of the operating budget in method can greatly decrease the steps a worker takes
distribution centres (DCs) that use a primarily manual and allows them to fulfil multiple orders on the same
approach to picking. While many different methodologies pass through the warehouse. A mobile picking cart is
for order fulfilment exist, it remains one of the most normally utilised.
critical activities affecting productivity, accuracy rates and
throughput. 5. Pick-to-box
While not a new picking methodology, pick-to-box has
1. Single-order picking been gaining popularity due to labour challenges. In this
The most commonly used picking method in DCs is also picking method, the picking process begins with selecting
the most time-consuming and least productive: single-order the box for the order at the beginning of the pick. The
picking. This is the practice of fulfilling one order at a time; WMS analyses the product’s size and dimensions and
a worker takes the order and walks through the warehouse, determines the appropriate box for the order. The worker
picking SKUs until the order is completed. They then take prints a shipping label and adheres it to the box, and the
the order to a pack and ship station and move on to the next worker can pick several orders in one pass through the
order. This method is popular because it is the least complex warehouse by using a picking cart. After all the orders
and requires minimal to no automation. are fulfilled, the worker seals the boxes manually or runs
them through an automatic sealing machine.
2. Zone picking
Using this method of picking, a warehouse is split into This method can effectively replace pack and ship
multiple zones. Orders come into a zone and are picked by stations, improve productivity and order accuracy, and
the worker stationed within that zone. When all products lower shipping material costs. A WMS with pick-to-box
in that zone are picked, they move on to the next zone for capability is needed as well as mobile carts, handheld or
additional picks or, if completed, to a pack and ship station. wearable scanning devices, and label printers.
This method is best for relieving congestion in pick lanes
and can improve productivity as an operation can group 6. Wave picking
promotional, seasonal and high-velocity products in one zone For fulfilling orders that have a high number of SKUs, a
as well as items that are likely to be ordered together. wave picking method may be the right strategy. Wave
picking uses a zone concept with orders released in
Slotting software and a warehouse management system waves to satisfy customer expectations and meet tight
(WMS) can be leveraged for this solution, as can robotics, like shipping windows. Workers will pick all the SKUs in one
autonomous mobile robots (AMRs), which can also be used zone for the current wave before moving to the next
to transport orders from zone to zone. zone. This method allows an operation to ensure that
orders will be available for shipping at the correct times,
3. Pick and pass although it will require the appropriate amount of labour
Using zone-picking principles, inventory is slotted into to be effective. Like zone picking, WMS and slotting
multiple zones. Orders are picked and placed in a tote or software can be useful.
shipping container, then the tote is passed on to the next
zone via a conveyor that runs through the zones. The tote will Which method is the best? That depends. Factors such
then travel to the next zone for additional items to complete as warehouse size, product characteristics, turn times,
the order or, if the order is fulfilled, it will travel to the shipping picks per order and customer and shipping expectations
area. play a part in determining the best picking methodologies
for your operation. Analysing internal and external data,
4. Batch picking forecasting demand and understanding labour needs can
If an operation fulfils orders with minimal SKUs, batch drive the selection of one method over another and help
picking can be a beneficial methodology to adopt. Batch transform your order fulfilment operations. •

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