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Order fulfilment has never been more under the spotlight than it is today. Big companies (such as Amazon) have raised consumers’ expectations. For warehouse companies to compete, every process has to be refined and streamlined. From receiving, through storage, to picking, packing and shipping, every aspect must be optimised so that the entire system runs smoothly and is as error-free as possible.
COVID-19 has led to a massive increase in online commerce, putting warehouse staff and systems under immense pressure. The effects of the pandemic have altered the way people buy goods and services, and this change is likely permanent.
While order picking should not be considered in isolation, it is an area that demands special scrutiny. If it is not optimised, it can form a bottleneck in the fulfilment process and produce mistakes that contribute to customer dissatisfaction. Not only is there the expense and time needed to deal with returns and complaints, but numerous complaints can quickly damage a company’s reputation and brand.
How to Optimize Picking
While picking strategies can be broken down into different types, such as zone picking, batch picking, and discrete picking, you’ll likely need a combination to find the best solution. Nothing should be set in stone, and constant reappraisal is needed if efficiency is maintained and unnecessary costs are reduced to a minimum.
Picking must be looked at holistically, from inventory arriving through to dispatch. The needs of picking should inform warehouse design, the choice of racking, the software implementation, and the equipment choice.
Racking is a very important factor. Inventory doesn’t just need safe and secure storage but also needs to be accessible. Correctly designed, installed, and maintained rack systems are fundamental. Make sure they are set up so that staff can flow through each area of the warehouse to find the goods they need without going back on themselves.
A barcoded system here will help ensure each order’s accuracy, and each item should be scanned again as it is prepared for shipping to minimise the likelihood of customers getting something they aren’t expecting.
Technology is helping. Warehouse management systems (WMS) are sophisticated packages that, when implemented correctly, add to efficiency in all areas, but no more so than in picking. When integrated with barcode scanning, voice recognition, radio-frequency identification (RFID) and other new technologies, picking can become fast, time-efficient and error-free.
Voice recognition, useful in many warehouse processes, shines when incorporated into picking. It increases productivity and accuracy and allows the workforce to work hands-free with real-time instructions. The equipment is not outlandishly expensive and often allows the pickers to inject information back into the system.
Many warehouses now video the packaging process. This is not to scrutinise the workers (though these videos can be used for training purposes) but to provide evidence of whether an order went awry if a customer reports a missing item. This can be beneficial for customer service since you’ll have evidence of whether you need to rectify the situation or prove to the customer that you did your part.
If your packing team find an item missing and have to call for someone to go and get it, or if they have more than they need, write a report on the incident. A simple log in a spreadsheet can help you see where individuals or entire teams are having issues, and you can rearrange that area of the warehouse to iron out these mistakes. Not all solutions need to be technologically advanced; they just need to help you strive to achieve perfection.
Automation is key in reducing human error. Although mobile robots and heavy-duty equipment require investment, the savings made long-term, both in speed and precision, will pay for the initial expense. Robots can complement the human warehouse pickers and allow them to maximise their efforts. Where this isn’t possible, look to your processes and software for automation solutions.
The warehouse management software (WMS) you use also needs to be adaptable; no two warehouse companies have the same needs. Warehouse managers need to fully understand the system in use and how to fine-tune it to adapt to changing circumstances. If your current software isn’t fulfilling all your needs, it’s time to look into a new solution.
Your racking system needs to abide by safety standards and be flexible enough to help you make the picking process as seamless as possible. If your racking is outdated or leads you to have an unsatisfactory picking order, consider investing in new racking to set up something that truly works.
In an optimised, well-run warehouse, even the smallest tweaks and additional conveniences for staff will help decrease the likelihood of mistakes.
