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What is parallel picking?

Parallel picking means that a customer order is first divided into several parallel partial orders by the warehouse management system. Later, the partial orders are picked in parallel by several pickers in the storage zones (picking zones) and then merged back into one order.

Details and simple explanation of parallel processing

In the merchandise management system, the order-oriented entry takes place first. In order to optimize the overall picking time (picking performance), the customer order is divided into several storage areas in parallel in the warehouse management system and prepared as a partial order.

In the picking process, each order is then picked in parallel in separate picking areas by several pickers in totes or shipping cartons (according to the pick list). For the picker, the parallel partial order is no different from a normal order.

Each item of the order is picked using the picking method used (e.g. picking with Pick-to-Light, Voice Picking, Pick-by-Point®, etc.). The goods are picked normally from the storage bin. To optimize the picking time in the process, the picking time, dead time and travel time should be as short as possible.

Once all the goods have been picked, the individual picking orders must be brought together again in the method. Sorters or conveyor technology are often used for this in order to save on distances.

Start of the parallel partial orders

In order to achieve an optimum start of the parallel partial orders, the material flow system must first calculate the optimum start time of the individual orders. The order throughput times in particular must be taken into account here. The aim of the optimization is to ensure that all parallel partial orders are completed as simultaneously as possible, thereby avoiding waiting times.

Merging the parallel partial orders

Once parallel picking has been completed in the warehouse, the individual orders are merged according to order. The distribution time for the picker should be as short as possible. The following methods can be used for this:

  • Picking methods for pallet distribution (put-to-point)
  • Accumulation of goods with a flow rack (optimum put-to-light picking method)
  • Manual sorting of goods with MDE (very outdated and slow)

Once all items have been combined in an order-oriented manner, shipping can take place. The selection of the optimum picking method is not covered in this article.

Advantages of parallel picking

Depending on the structure of the supporting picking systems, parallel picking has the following advantages:

  • High performance thanks to order-oriented picking in separate storage zones (important: correct ABC analysis).
  • Short base times by dividing the tasks among several order pickers.
  • Optimal use of picking methods such as Pick-to-Light, Voice Picking, Pick-by-Point®, etc. when picking partial orders.

Disadvantages of parallel picking

The disadvantages are defined as follows:

  • This method only makes sense for large warehouses with many storage zones (picking zones) and many items.
  • The allocation of customer orders to sub-orders is not always optimally feasible due to the warehouse structure.
  • High technical effort required to merge the parallel orders.

Conclusion

Parallel picking is suitable for large warehouses with many storage zones and a high level of automation (Pick-to-Light, Voice Picking, conveyor technology, sorter systems) for fast picking. Several order pickers can process a customer order simultaneously. Merging the partial orders is time-consuming and must be controlled by the material flow system together with the picking process.

Do you have any further questions about your order picking?

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