Batch picking is a strategy for warehouse operations which can improve productivity, order fulfilment times and safety.
How does batch picking work?
In single order picking, also known as discrete picking, the warehouse operator moves through the locations of the warehouse with their picking trolley or cart, selecting each item or Stock Keeping Unit (SKU) on a particular order until the order is complete and can be moved to the packing and shipping team. The operator then repeats the process to pick the next order.
In batch picking, a number of different orders are combined, and at every location the operator will collect enough of each SKU to meet all the orders. In other words, instead of walking through the warehouse, say ten times to pick ten different orders, they can make a single journey through the warehouse to pick all ten orders.
On the face of it, this is a clear improvement in efficiency, but of course a number of factors must be assessed to optimise the process and to ensure safety.
Implementation considerations
Nature of the SKUs to be picked
This is fundamental to the choice of picking strategy. Key aspects are the shape and size of the SKUs, and any special considerations, such as fragility or potential dangers/special procedures in handling them. Larger-sized items are likely to reduce the number of orders which can be combined in a single batch.
If there are wide variations in the size or nature of the SKUs which may be requested in a single order, it may be impractical to complete the order on one collection run. This is because both the design of the picking trolleys or the necessary retrieval and handling methods may vary between the items.
In these circumstances, batch picking can be combined with another strategy known as zone picking, in which SKUs of a different size or nature are stored in different areas, or zones, of the warehouse. Typically, operators will be allocated to a particular zone according to their skill set. Working in one zone also reduces their walking time, which in turn improves productivity. The batch picking process could move consecutively from zone to zone until it is complete, or alternatively the picking for that batch of orders could be carried out concurrently across all zones and the SKUs from the different zones combined later into the finished orders.
Using batch picking with automation
The implementations of automation vary but an example is as follows. The Warehouse Management System will create a batch of orders based on order profile (e.g. orders with a similar selection of SKUs or the same customer delivery date). A box for each order in the batch is set out at a picking station located centrally amongst automated storage devices which will retrieve the various SKUs. The operator will deal with each different SKU in the batch in turn. A pick light on the storage device for a particular SKU will show the operator how many items of that SKU to collect from the device. The operator takes the items back to the order station where put lights placed on the order boxes show them which orders require that particular SKU. Once that SKU has been placed in each of the relevant boxes, the operator moves on to deal with the next one.
Design of picking trolleys and picking carts
The appropriate design and construction of picking carts and trolleys is crucial to the success of a batch picking operation. They need to fit the warehouse environment, the characteristics of the SKUs and the scale of the batches.
Benefits of batch picking
Increased productivity
Batch picking improves the efficiency both of operators and the warehouse equipment they use. Bottlenecks are reduced – e.g. one operator collecting five items is better than five operators queuing to retrieve one item.
Faster order fulfilment
Reduced processing times improves order turnaround and customer satisfaction.
Improved safety
Less traffic about the warehouse reduces the chance of accidents and collisions.
Increased staff satisfaction
Team members know they are working more productively and with less unnecessary walking, which may in turn have a positive impact on staff retention.
Better workload management
Batch picking makes it easy to deal with variations in the numbers of orders a warehouse receives, for example by scaling batch sizes. It allows work to be allocated more easily to pickers with the necessary skills to handle the SKUs in a particular batch.
Could batch picking be right for your business?
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