Most warehouses in the U.S. are still using RF or paper based order picking solutions, despite the huge efficiencies and cost reductions that are possible with automated picking systems. In truth, just about 20% of storage facilities throughout the country make use of advanced services like voice directed or pick to light systems. These types of solutions can have a remarkable impact on productivity.
The Business Case For Automated Picking Systems
In the majority of warehouses, picking is a labor-intensive job where a picker gets an actual paper list of directions specifying the products to pick and their locations. They proceed to the specified storage location, evaluate their paper list to figure out the number of items they need from that pick face, get the products, check the product off of the list, and then transport the products for packing.
Just moving around a warehouse can take up to 65% of a manual order picker’s day as they walk or ride about the warehouse. These antiquated methods make order picking the most labor-intensive function in a typical storage facility. Oftentimes, the majority of a common warehouse’s operating expenditures can be traced to order picking. That number is effectively rising as e-com spurs additional picking demand from storage facilities.
Nearly all storage facilities have some picking requirements. Almost 50% deal with a mixture of pallets, cases, split cases and pieces. In fact, less than 10% of all warehouses throughout the nation handle strictly whole pallet orders. And even though many warehouses bear huge picking costs, only 20% have moved away from standard RF and paper-based picking solutions.
Innovations in Picking Technology
In the last 10 years there have been excellent advances in picking technology, varying from IoT+ RFID to enhanced reality smart glasses. The two most extensive and developed technologies, however, are light directed and voice directed picking options. Each has a convincing use case in particular circumstances, and some storage facilities even use both methods.
Fully actualizing technology-based picking solutions can be capital intensive. However, ROI models for picking automation are strong. Many projects have a fast payback and can produce substantial savings in labor and pick errors for several years to come. A 2018 study showed that companies that utilized voice, light or RFID based picking solutions minimized pick errors by approximately 67%.
Pick To Light
Pick to light systems are perfect for zone picking or high order volume, high speed operations. Racks are furnished with LEDs that indicate pick quantities and locations, and workers tap these lights to validate selections and volumes as they make their way along a pick route.
Light directed systems are not as flexible and more expensive than voice directed systems, yet when carried out correctly they can significantly enhance picking velocity and precision. According to MHI, most pick to light applications gain approximately 30-50% in pick rate efficiency.
Voice Picking System
Voice picking solutions are perfect for storage facilities that stock a greater selection of SKUs dispersed across larger buildings. Employees can move about a warehouse hands-free–they don’t need to carry a portable device or sheet of paper.
Picking directives are relayed by the warehouse management system through an earpiece or headset, and the order-picker answers verbally to verify each pick. There is no device to hold, no screens to read, no barcodes to scan, and no verification buttons to click. The whole procedure is performed through voice commands and verbal verification.
Order Picking Automation Systems Near Me
If you would like more information on order picking innovation for your warehouse, call a Welch Equipment Company automation consultant today!