Order picking systems [2023]
Picking systems should provide optimal support for employees and save costs.
Order picking systems are very important in warehouses or production facilities and are designed to support employees. The requirements vary greatly. For this very reason, it is not possible to create a universal system. First plan, then select the order picking techniques.
We will introduce you to the LUCA systems and give you an insight into the various possibilities. We will also explain which systems are compatible with each other and how they can best be used.
What are picking systems?
Imagine a large warehouse. Many items or semi-finished products are stored on shelves or pallets. The customer or production department orders specific items.
If the goods are available in the storage location, the Warehouse Management System generates an order. Now the items must be collected from the storage bins.
This is precisely where picking systems come into play. They are designed to support warehouse staff. Read more about picking on Wikipedia.
The best picking systems compared?
Many scientists and researchers have been studying this question for several years. The answer is very simple:
None of the picking systems is the best. The system must suit the requirements.
It is simply not possible to build a single solution that can fulfill all tasks. Every warehouse is different, so it is almost impossible to compare them.
The standards include:
- pick-by-light
- put-to-light
- Voice Picking
- Pick-by-Point®
- Pick-by-Frame®
- Pick-by-Cart
- Pick-by-Watch
Others are new and highly innovative.
The most important differences and comparisons
First and foremost, picking systems must be differentiated according to the type of automation. In some warehouses and production facilities, it does not make sense to use complex and expensive automation. On the other hand, a high-performance shipping warehouse cannot be fully operational without automation.
This results in the following comparison of picking systems:
- Fully automatic
- Semi-automatic with conveyor technology
- Manually
Fully automated picking
Fully automated picking can only be used for certain items and at high throughput rates. The high costs must justify the investment. The goods are picked fully automatically and transported to the packaging area, e.g., via a conveyor system.
Highly qualified technical personnel are required to operate a fully automated system. Constant monitoring of the systems and immediate response to malfunctions are essential.
Due to their high cost, fully automated picking systems are not very common.
Semi-automatic order picking with conveyor technology
One example of this is classic shipping systems. Automatic or manual carton erectors are used to prepare the cartons. The cartons are transported via a conveyor system to the individual picking zones, where the appropriate picking systems—pick-by-light, Pick-by-Scan, Pick-by-Watch, etc.—are used.
We distinguish between:
- Man as a commodity
- Goods to the man
Semi-automatic picking systems are widely used. The costs of hardware and implementation are manageable. The systems are not technically complex. Annual maintenance is usually sufficient for these systems.
Manual picking
People are always at the forefront of manual picking systems. The technical equipment should make the picker's work easier, guide them, and signal any errors.
In many warehouses, only forklifts or order picking trucks are used. Different racking technologies are used here (pallets, flow racks, shelving racks, etc.). For this reason, the order picking systems must also be designed differently.
In a picking warehouse where only pallets are picked, forklift terminals are perfectly adequate. On the other hand, small parts and small containers are stored on shelves or flow racks. In this case, picking trolleys are more suitable.
Type of manual picking
One of the important additional criteria for the correct selection of manual picking systems is the type of picking. There are the following differences here:
- Single order picking
- Multi-order picking
Frequently used manual picking methods include:
- pick-by-light
- Voice Picking
- Pick-by-Frame®
- Pick-by-Point®
- Pick-by-Watch
- Pick-by-Tablet
Proper planning and design
We often find that people are very fixated on a particular technology when they first make an inquiry. Pick-by-Vision a fad. The proven technologies are pick-by-light, Voice Picking, Pick-by-Point, and Pick-by-Frame. Unfortunately, the focus is often on the technology rather than the concept.
Combination of systems
Some connections between the systems are particularly efficient. The problem with checksums in classic Voice Picking very good example Voice Picking this. Compared to other solutions, high-performance employees have to "talk" to the system a lot. Confirmation of the aisle, confirmation of the checksum, confirmation of the quantity, confirmation of the batch, etc.
All of this takes a lot of time. The problem with orientation and checksums is solved by combining Voice Picking Pick-by-Point®. The Pick-by-Point® light shows the storage compartment with a large dot. The employee then only confirms the number of items picked. The combination of picking systems is very efficient in this case.
Advantages and disadvantages of picking systems
Advantages:
- Employee support
- Quality assurance
- Enable high performance
- Always up-to-date inventory control
Disadvantages:
- High costs, depending on the degree of automation
- Annual maintenance costs
- Often inflexible due to complex technical design
Why is LUCA different?
There are many providers of individual systems on the market. However, this is rarely enough to offer an optimal solution. We supply all systems from a single source and control them centrally via our LUCA server software.
LUCA systems control order picking and material flow throughout entire plants. We also build individual and small-scale systems.
Conclusion
LUCA offers many picking systems. In some cases, it makes sense to use the individual systems in combination. The focus during planning should be on the concept and not just the technology. Talk to us.
Further topics …
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