Multi-Order-Picking with Pick-to-Light

What is Multi-Order-Picking?

Multi-Order-Picking is a picking method in which several orders are picked simultaneously by one picker. The individual picking orders are combined into a batch on a picking trolley and are processed simultaneously.

When is Multi-Order-Picking used?

If several orders can be served from the same storage bins due to the order structure, the picker can shorten his routes and process several picking orders at the same time. This saves an enormous amount of time and increases picking performance and efficiency.

Problems with batch picking

Imagine that there are many orders on the picking trolley (usually 9-16 items). You have a pick list in your hand and now have to find the individual storage compartments according to the list. As an order picker, you know your warehouse and have no problem finding the storage bins. You will find your bin very quickly. Perhaps the total quantity is also shown very clearly in the list.

You remove the items from the storage compartment and now ... you have a problem! The total quantity must be distributed appropriately among the individual orders. So now the search begins.

1. First of all, you must read off the appropriate partial quantity from the pick list.
2. Secondly, you have to read the order and identify the appropriate box or container on the picking trolley.
3. Thirdly, you must count out the appropriate number of pieces from your total quantity and store them.

All these activities happen simultaneously and require maximum concentration. This often results in mistakes, which are understandable when working for 8 hours.

Use of Pick-to-Light for batch picking

A Pick-to-Light system can be used as a very good aid for Multi-Order-Picking . The software of the Pick-to-Light system is responsible for the entire picking process. There are two variants of support here:

1. Pick-to-Light-Compartment displays on the picking trolley

The best method for supporting batch picking with a picking trolley is to use Pick-to-Light displays directly on the picking trolley itself (Pick-by-Cart) or on an auxiliary structure (Pick-by-Frame). For this purpose, the trolley or frame constructions are equipped with a battery, WiFi and displays.

After order activation, the info display first shows the picking location. Once the removal has been confirmed (e.g. by a barcode scanner), the compartment displays for the individual orders light up and show the appropriate number of items directly on the box or container.

The picker only has to distribute the displayed quantities to the individual orders and confirm the deposit at the acknowledgement button.

Set up for Multi-Order-Picking

Before the picking orders are started using the Multi-Order-Picking method, the individual cartons or totes must be positioned on the picking trolley and assigned to the orders. The process is also supported by Pick-to-Light and is therefore very quick and easy.

2. Pick-to-Light Displays at storage locations

If the number of picking locations in a work area is manageable (20-30), the Pick-to-Light displays can be installed statically at the storage locations rather than on the picking trolleys.

In this case, the target compartment in the picking trolley is displayed at the same time as the removal quantity (e.g. "3 - 5" -> three items in compartment 5). The deposit can be confirmed directly at the acknowledgement button or with a barcode scanner on the deposit compartment.

This picking method is rarely used and has so far only been used by us in the automotive industry. In these cases, the removal quantity was always = 1, so that only the storage compartment was shown on the Pick-to-Light display.

Conclusion

The Pick-to-Light system is very helpful at Multi-Order-Picking : minimizes errors, increases performance and ensures the quality of batch picking enormously. The employees are more relaxed and much happier.