Manual Order Picking Methods
Traditionally, order picking has been a manual process, relying on warehouse staff to retrieve items. While manual picking can work for smaller operations, it becomes increasingly challenging as order volumes grow. Let’s take a look at the primary manual order picking methods:
Single Order Picking
This method involves one picker handling one order at a time. It’s simple and suitable for small-scale warehouses with low order volumes. However, single order picking can be time-consuming and inefficient when dealing with large numbers of orders or high pick densities.
Zone Picking
In zone picking, the warehouse is divided into zones. Each picker is responsible for a specific zone and retrieves items only within their designated area. This method reduces travel time for pickers and works well in medium to large warehouses. However, it requires good coordination to ensure all items are collected for each order.
Batch Picking
Batch picking involves picking items for multiple orders simultaneously. It’s ideal for high-order volumes with similar items in demand. This method increases efficiency, but requires additional sorting to ensure orders are accurate.
While these manual methods have their place, the demand for speed and accuracy in modern warehousing often pushes businesses to explore automated solutions.
Automated Order Picking Methods
Automation has revolutionised the warehousing industry, offering improved efficiency, accuracy, and scalability. Some of the key technologies for automated order picking include:
Automated Storage and Retrieval Systems (ASRS)
ASRS are computer-controlled systems that automatically retrieve and store items. They’re highly efficient, reducing the need for human intervention and minimising errors. These systems work well in high-density storage environments where speed and accuracy are critical.
Automated Mobile Robots (AMRs)
Automated mobile robots use advanced sensors and AI to navigate the warehouse autonomously. Unlike traditional fixed systems, AMRs are highly flexible and can adapt to changing warehouse layouts. They can pick and transport items, significantly reducing the workload of human pickers.
Automated Guided Vehicles (AGVs)
AGVs are similar to AMRs, but operate on fixed paths within the warehouse. They’re ideal for moving heavy loads and are often used to complement other automated systems. AGVs excel in warehouses with repetitive transportation needs, such as moving pallets from storage to packing areas. These vehicles reduce the physical strain on employees, lower the risk of handling-related injuries, and ensure consistent transportation speeds. Their precision and reliability make AGVs a valuable asset for warehouses striving to enhance productivity and maintain smooth operations. Additionally, AGVs can integrate seamlessly with other technologies, further supporting warehouse optimisation.
Big Box have an outstanding range of autonomous lift trucks designed to handle heavy pallets with ease. They’re an excellent choice for businesses looking to streamline their operations without compromising on safety or efficiency.
The Hybrid Approach: Combining Manual and Automated Solutions
While full automation is ideal for some, many businesses find a hybrid approach to be the most practical solution. Hybrid systems combine manual processes with automation to provide flexibility and cost efficiency. One popular example is Pick-to-Light technology.
Pick-to-Light is a semi-automated system where lights guide pickers to the correct storage locations. Once an item is picked, the light turns off, ensuring accuracy and reducing picking times. This system retains the human element while leveraging technology to enhance performance.
Hybrid solutions are particularly useful for businesses in transition or those with diverse product ranges. They allow gradual adoption of automation without significant upfront investment, offering an excellent balance between technology and human skills.
The Benefits of Automated Order Picking
Regardless of the approach, transitioning from manual to automated order picking delivers tangible benefits, including:
- Improved Accuracy: Automation reduces human error, ensuring orders are accurate and customers are satisfied.
- Increased Efficiency: Automated systems speed up the picking process, enabling faster order fulfilment.
- Scalability: As your business grows, automated solutions can easily handle increased volumes.
- Better Resources Allocation: Automation frees up staff for higher-value tasks, boosting overall productivity.
- Warehouse Optimisation: Automated systems make for better use of space and streamline operations.
For businesses like yours, automation isn’t just about keeping up – it’s about getting ahead.
Is Automation Right for You?
From manual systems like single order picking and zone picking, to cutting-edge technologies like ASRS, AMRs and AGVs, there’s no shortage of operations when it comes to order picking. Hybrid solutions, such as pick-to-light, offer an excellent stepping stone for those not ready to fully automate their operations.
At Big Box, we understand that every business is unique. Whether you’re looking to explore full automation or considering a hybrid approach, our team is here to help you find the right solution for your warehouse needs.
Get in touch today to discover how automated order picking can transform your warehouse operations and drive your business forward.