Understanding The Role of Pick Routes In Order Fulfillment
The shorter the distance of the pick route, the faster order fulfillment, higher picking performance & ultimately higher warehouse productivity.
Pickers navigate the warehouse to retrieve items, and these routes can be complex, with various parameters to consider:
- The type and number of items to be picked
- Item locations which are identified by aisle, shelf, and bin numbers as well as height location - some items may be stored on higher shelves
- Bulkier or heavier items may need specific handling procedures, such as palletization (with these items typically placed at the bottom) or specialized equipment (forklifts)
- Priority assignments to ensure timely fulfillment of critical orders, especially for time-sensitive or urgent shipments
- Picking sequence
- The direction in which the picker enters the picking sequence to pick items
Why Manual Picking Can't Compete In Today's Order Fulfillment
Manual picking processes have their limitations and inefficiencies, particularly when it comes to orders containing a large number of items to be picked across a warehouse.
This number could be anywhere from 10 to 100. The higher the number of items to be picked in one travel, the bigger the gap of human chosen pick routes and optimized pick routes.
The Challenges of Human Chosen Pick Routes
- Long travel distances: Human-led decisions can result in 30% longer pick distances than necessary. This number depends on the number of items to be picked for the picker.
- Order Clustering: Efficiently grouping orders based on the similarity of items or their locations can be difficult just by gut feeling. It can be challenging to cluster multiple orders together, especially when it means picking hundreds of items, while also figuring out the best route to pick them and considering factors like size & weight.
- Impact on the bottom line: Inefficient picking routes lead to higher labor costs and longer order processing times. Pickers spend up to 60% of their time picking only on walking – walking in between items.
Warehouse Picking Route Optimization
The goal of picking route optimization is to minimize the time and effort required to fulfill orders while maximizing accuracy and efficiency.
In some cases, the picking route and wave optimization process can cut down travel distance by up to 45% and help companies meet the demands of an increasingly demanding customer base.
The picking route optimization solution can reveal valuable insights into warehouse operations by analyzing data such as pick frequency and travel time.
- Picking Heatmaps: These heatmaps identify areas in the warehouse where congestion is most likely to occur, helping managers optimize pick routes to reduce bottlenecks. Slotting
- Arrangements: PPO software analyzes pick density and suggests better slotting arrangements to maximize space utilization and increase efficiency.
- Item Correlation: By predicting which items are frequently picked together, the software positions related items close together to reduce travel time and enhance pick efficiency.
Learn how we reduced walking distances on the warehouse floor by an average of 15 to 20% compared to non-optimized routes at Bleckmann.
Bottom Line
Make informed decisions about warehouse operations, improve productivity, and achieve cost savings. Stay competitive and meet the demands of your customers more efficiently and faster.