The majority of warehouses in the U.S. are still utilizing RF or paper based order picking systems, despite the huge efficiencies and expense decreases realized by automated picking systems. Only about 20% of storage facilities across the nation use advanced options like voice directed or pick to light systems. These kinds of systems can have a tremendous effect on profitability.
The Business Case For Automated Picking Systems
In a lot of warehouses, picking is a labor-intensive process where a picker receives an actual paper list of instructions laying out the products to pick and their specific locations. They move to the specified storage location, examine their paper list to determine how many items they need from that pick face, get the items, tick the product off of the list, and then transport the products for packing.
Just getting around a storage facility can use up to 65% of a manual order picker’s day as they walk or drive about the building. These inefficiencies make order fulfillment the most labor-intensive task in a conventional storage facility. In many cases, over half of a common warehouse’s operating expenditures can be traced to order fulfillment. That number is actually increasing as e-com spurs additional picking demand from warehouses.
Nearly all storage facilities have some picking requirements. Almost 50% deal with a blend of pallets, cases, split cases and pieces. In fact, less than 10% of all warehouses across the country handle strictly whole pallet orders. And although most warehouses bear huge picking expenses, only 20% have actually moved away from conventional RF and paper-based picking solutions.
Innovations in Picking Technology
In the last 10 years there have been excellent advances in picking innovation, ranging from IoT+ RFID to augmented reality smart glasses. The 2 most prevalent and developed technologies, however, are light directed and voice directed picking approaches. Each has a convincing use case in certain circumstances, and some storage facilities even employ both techniques.
Fully incorporating technology-based picking solutions can be capital intensive. Nevertheless, ROI models for picking automation can be convincing. Many projects have a rapid payback and can produce substantial savings in labor and pick errors for many years to come. A 2018 research study showed that businesses that employed voice, light or RFID based picking solutions lowered pick errors by approximately 67%.
Pick To Light
Pick to light systems are ideal for zone picking or high order volume, high speed facilities. Racks are equipped with LEDs that indicate selection quantities and slots, and employees tap these lights to confirm picks and volumes as they make their way down a pick path.
Light directed solutions are less flexible and more expensive than voice directed systems, but implemented correctly they can significantly enhance picking velocity and accuracy. As reported by MHI, most pick to light applications achieve approximately 30-50% in pick rate performance.
Voice Picking System
Voice picking options are best for warehouses that fill a more extensive assortment of SKUs dispersed throughout larger warehouses. Workers can move about a building hands-free–they don’t need to carry a handheld device or piece of paper.
Picking instructions are relayed by the WMS through earphones, and the order-picker replies verbally to validate each pick. There is no equipment to carry, no screens to view, no barcodes to scan, and no verification buttons to click. The whole procedure is performed through voice commands and spoken confirmation.
Order Picking Automation Systems Near Me
If you would like more details on order picking technology for your operation, call a Welch Equipment Company automation expert today!