Case Picking Optimization Methods and Solutions

Case picking optimization is a crucial step in maximizing warehouse efficiency. By implementing the right strategies, you can reduce labor costs and improve order fulfillment rates.

One of the most effective methods is to use a zone picking strategy, where cases are stored in a specific zone based on their destination. This can reduce walking distances and increase productivity.

According to a study, a well-implemented zone picking system can reduce picking times by up to 25%. By minimizing the time spent searching for cases, you can get orders out the door faster and improve customer satisfaction.

A key consideration when implementing zone picking is to ensure that cases are stored in a logical and organized manner, with similar products grouped together. This can make it easier for pickers to find what they need and reduce errors.

See what others are reading: Wood Wine Cases

Optimizing warehouse processes is crucial for efficient case picking. By implementing a warehouse management system (WMS), you can optimize picking routes and reduce errors.

Explore further: Pick Pack and Ship Warehouse

A WMS analyzes orders and determines the most efficient path based on the locations of items. This ensures that pickers are directed to bins that are adequately stocked, minimizing backtracking and delays.

Manual case picking is suitable for low-volume orders, but struggles with rising demand. Automated Storage and Retrieval Systems (ASRS) like the Exotec Skypod system offer the optimal mix of performance and flexibility for case picking operations.

The Skypod system boosts throughput up to 5x compared to manual methods, with the ability to retrieve any case within two minutes. Its modular design adapts to varying throughput, storage, and industry needs.

To optimize warehouse layout, place high-demand items closer to packing stations and implement zone picking. This minimizes the travel time needed for pickers.

Here are some key benefits of optimizing warehouse processes:

By implementing these strategies, you can significantly improve your warehouse's efficiency and accuracy.

Developing a clear vision for an optimal warehouse process can be challenging, but it's a crucial step in achieving efficiency gains. A good starting point is to conduct an operations assessment to document how and why you're doing things today, which can help identify specific time-saving opportunities.

A warehouse management system (WMS) can also play a key role in optimizing warehouse operations. By analyzing orders and determining the most efficient picking routes, a WMS can reduce errors and minimize backtracking.

In order to maximize case picking productivity and accuracy, it's essential to optimize your process. This can be achieved by using a WMS to direct pickers to adequately stocked bins, minimizing delays and backtracking.

Check this out: Warehouse Pick and Pack

Determining an optimal warehouse strategy can be challenging, but it's essential for maximizing productivity and efficiency.

Conducting an operations assessment can help you identify specific process improvement opportunities in your facility.

A good way to get started is to document how and why you're doing things today to identify specific time-saving opportunities in your existing process.

This will give you a clear picture of what an optimal process will look like in your DC and help you project the potential efficiency benefits of a new process.

It's more challenging to estimate the potential gains from process optimization, but with an operations assessment, you can begin to estimate your end-state productivity gains.

To help with this, Lucas offers an operations assessment service that can identify specific process improvement opportunities in your facility.

In many warehouses and distribution centers, there is a struggle to meet productivity requirements without optimizing their case picking processes.

Manual case picking is suitable for low-volume orders but struggles with rising demand, leading to the adoption of Automated Storage and Retrieval Systems (ASRS) like the Exotec Skypod system.

This system boosts throughput up to 5x compared to manual methods, with the ability to retrieve any case within two minutes, making it an optimal mix of performance and flexibility for case picking operations.

If this caught your attention, see: Pick and Pack System

A Warehouse Management System (WMS) can be a game-changer for your warehouse operations. It optimizes picking routes and reduces errors by analyzing orders and determining the most efficient path based on item locations.

Readers also liked: Warehouse Pick Pack Work

A WMS also accounts for real-time inventory levels, ensuring pickers are directed to bins that are adequately stocked, which minimizes backtracking and delays. This leads to faster order processing times and higher productivity.

With a WMS, you can reduce errors and improve efficiency by directing pickers to the right bins at the right time. This is especially important in high-volume warehouses where even small errors can add up quickly.

By leveraging a WMS, you can automate many of the manual tasks associated with warehouse operations, freeing up staff to focus on higher-value tasks. This can lead to significant productivity gains and cost savings.

Here are some key benefits of using a WMS:

Improving warehouse performance requires a strategic approach that considers various factors, including technology, layout, and employee training.

Conducting an operations assessment can help identify specific process improvement opportunities in your facility, allowing you to develop a clear picture of what an optimal process will look like.

Automation technology, such as barcode scanners and pick-to-light systems, can greatly improve case-picking efficiency by enabling precise identification of items and guiding workers quickly and accurately to the correct cases.

A well-designed warehouse layout can minimize travel time by storing high-demand items closer to picking stations and grouping them by frequency of use or picking patterns.

Providing ongoing training to staff on the latest systems, tools, and best practices can maintain high productivity and accuracy in case-picking operations.

Here are some strategies for improved case picking:

By implementing these strategies, you can significantly boost the efficiency of your case-picking operations and improve overall warehouse performance.

Storage and Palletization is a crucial aspect of case picking operations. The most common and efficient method of storage for case picking is by pallet, which allows for the highest-density storage in general.

Pallet storage is often used in warehouses where pickers can easily retrieve cartons stacked on top of each other on the floor or on a rack. This method enables the highest pick rate per hour or lowest time per pick in case picking.

Case picking involves selecting individual cases or cartons from shelves, pallet positions, or carton flow, which is a type of shelving that utilizes a gravity-fed, rear-loading design.

Proper labeling is essential for efficient picking, allowing pickers to quickly identify the correct cases.

Clear and consistent labeling reduces errors and speeds up operations.

Efficient packaging minimizes the need for repacking or adjusting cases during the picking process.

This helps to enhance order accuracy and customer satisfaction.

Clear labels help pickers quickly identify the correct cases, making the picking process faster and more accurate.

The SSI Case Picking system is a game-changer for food retailers looking to optimize their store deliveries. By using this system, retailers can ensure perfectly packed pallets and trolleys for efficient store delivery.

SSI Case Picking enables the automatic compilation of mixed pallets with a wide range of items and packing variants for store-optimized deliveries. This is made possible by proven technologies that are in constant development.

The modular palletizing system is characterized by efficiency, flexibility, and scalability. We can also tap into our in-house software and service competence to adapt the standardized modules of the SSI Case Picking system to meet the demands of the food market segment.

Consider reading: Case Picking System

Here are some of the key benefits of the SSI Case Picking system:

The SSI Case Picking system is a unique system configuration for automatic, store-optimized palletizing of all kinds of retail units.

Pallet storage is the most common and efficient method for case picking operations, allowing for the highest-density storage and the highest pick rate per hour or lowest time per pick.

It involves a warehouse picker retrieving cartons stacked on top of each other either on the floor or on a rack.

Pallet storage is ideal for large bulk orders, such as wholesale restocking, as it allows for quick movement using forklifts.

This method is efficient for pallet picking, which is the process of moving entire pre-packed pallets of a single product from a rack or floor storage.

In a pallet storage system, cartons can be stacked on top of each other, making the most of available space.

Pallet storage is a space-saving solution that can help optimize warehouse space and streamline operations.

Case picking offers numerous benefits that can significantly improve warehouse operations.

Boosting warehouse picking productivity is one of the main advantages of case picking, allowing warehouse employees to manage multiple items in a single motion. This method significantly speeds up the order fulfillment process.

By storing and picking cases rather than individual SKUs, warehouses can better utilize vertical and horizontal space, reducing the footprint needed for inventory. This compact storage method allows for more items to be stored in the same amount of space and improves the organization and accessibility of goods.

Case picking also reduces overall cost per unit by lowering labor costs and warehousing expenses such as lighting, heating, and cooling.

Here are the key benefits of case picking:

SSI Case Picking offers numerous benefits to warehouse operations. It optimizes the picking process, allowing warehouse employees to manage multiple items in a single motion, significantly speeding up the order fulfillment process.

Boosting warehouse picking productivity is a major advantage of SSI Case Picking. By reducing the time spent on each pick, labor costs decrease, making operations more cost-effective and enhancing profitability.

Reducing storage space per item is another key benefit. When cases are stored and picked instead of individual SKUs, warehouses can better utilize vertical and horizontal space, allowing for more items to be stored in the same amount of space.

This compact storage method also fosters sustainability by decreasing warehousing expenses such as lighting, heating, and cooling. As a result, overall cost per unit decreases.

Here are some of the key benefits of SSI Case Picking at a glance:

Implementing effective case-picking strategies also enhances efficiency, simplifying the shipping process by reducing handling steps. It improves order accuracy, lowering the potential for errors, and optimizes space utilization, requiring less space than storing individual items.

Continuous Inventory/Transparency is a game-changer for any business that deals with inventory management.

All item retrievals from every storage area and at every station are booked in the WAMAS system, giving you complete visibility into your inventory.

This includes batch data and best before dates, so you can make informed decisions about what to keep and what to dispose of.

With this level of transparency, you'll always know what's in stock and what's running low, eliminating the risk of stockouts and overstocking.

You'll be able to dispose of your current inventory with confidence, knowing exactly what you have and when it's due to expire.

Implementing automated storage and retrieval systems (ASRS) can significantly reduce manual labor and minimize picking errors. These systems automate the storage and retrieval of items, optimizing space usage and improving inventory management.

Automated case picking can boost efficiency by operating continuously, eliminating breaks and fatigue, which significantly boosts productivity. Consistency and accuracy are also ensured, as automation reduces the risk of human error.

Recommended read: Case Conveyor Systems

Modula offers various automated case picking solutions, including the Put to Light System, Modula Picking Station, Modula Picking Cart, and Modula Picking App. These solutions can speed up the picking process and improve accuracy for large batch orders.

Here are some benefits of automated case picking:

Incorporating scan verification into your warehouse operations can significantly improve accuracy and efficiency. Scanning barcodes with handheld or fixed-location RF scanners and camera-based imagers instantly validates items.

This approach dramatically increases accuracy compared to manually entering product codes or visually checking SKU numbers. In fact, scanning verification reduces human picking errors and speeds up the process, potentially eliminating the need for later quality checks.

These devices can read codes on pick lists, single units, cases, pallets, totes, and storage positions, ensuring that workers pick the correct item for the order. This means that inventory levels are accurately maintained and orders are accurately picked.

Automated scan verification eliminates the need for manual processes, which can significantly reduce labor costs and increase productivity. By reducing human error, you can also ensure consistency and accuracy in your warehouse operations.

You might enjoy: Order Picking Accuracy

Automated case picking is a game-changer for warehouses. It can operate continuously, eliminating breaks and fatigue, which significantly boosts productivity.

Automated systems can process orders much faster than manual picking, with the ability to operate 24/7 without rest. This means that orders can be fulfilled quickly, even during peak periods.

One of the biggest advantages of automated case picking is its ability to reduce human error. Automation ensures that orders are accurately picked, and inventory levels are accurately maintained. This leads to increased accuracy and reduced waste.

Automated case picking can also significantly reduce labor costs over time. By automating the picking process, the need for manual labor is greatly reduced, resulting in lower overall labor costs.

Here are some benefits of automated case picking at a glance:

Automated case picking is particularly beneficial for high-volume environments, where manual picking might not be efficient or accurate. However, it's essential to consider the specific needs of your warehouse when deciding between manual and automated case picking.

Consider reading: Automated Pick and Pack System

Implementing warehouse technology can be a game-changer for your business. Automated storage and retrieval systems (ASRS) can significantly reduce manual labor and minimize picking errors by automating the storage and retrieval of items.

These systems can optimize space usage and improve inventory management by automatically adjusting storage locations based on frequency of use and other factors. By doing so, they can help you make the most of your warehouse space.

Modula offers various automated case picking solutions to enhance order efficiency, accuracy, and reliability. Their solutions include the Put to Light System, which features an OLED configurative display and directs operators using a scanner and LED lights, showing exactly where to place items.

The Modula Picking Station leverages the Put to Light system, facilitating batch picking and order consolidation. It enhances accuracy through options for scanning or touch light validation. The Modula Picking Cart is a mobile cart equipped with shelves, wheels, and Put to Light controllers, along with battery backup and Wi-Fi connectivity.

You might enjoy: Order Picking Systems

Here are some of the automated case picking solutions offered by Modula:

In addition to these solutions, incorporating scan verification can also increase accuracy and speed up the picking process. Automatic identification and data collection (AIDC) technologies, like handheld or fixed-location RF scanners and camera-based imagers, can instantly validate items by scanning barcodes. This approach reduces human picking errors and speeds up the process, potentially eliminating the need for later quality checks.

Directed picking is a system that guides pickers step by step to the item on the pick list. It's typically useful for higher volume piece picking operations.

Light-directed picking uses indicators at each shelf location that light up when a pick list shows an item or carton from that location.

Voice-directed picking produces an audible version of the pick list, allowing pickers to remain focused on collecting items.

There are two types of directed picking: light-directed and voice-directed. Here's a brief comparison:

Both types of directed picking can help reduce errors and improve efficiency in warehouses.

Collaborating with a 3PL provider can significantly improve your case picking operations. They can offer advanced warehouse management solutions and provide additional resources during peak seasons.

A 3PL provider can integrate their own automated warehouse picking solutions to streamline your operations. This can lead to reduced travel time and accelerated picking processes.

By implementing best practices and optimizing your warehouse layout, you can improve efficiency and reduce costs.

A different take: Pick and Pack Solutions

Collaborating with a 3PL provider can be a game-changer for your business. A 3PL provider can offer advanced warehouse management solutions that can improve efficiency.

They can provide additional resources during peak seasons, which is especially helpful if you're scaling your operations. This can help you handle increased demand without sacrificing quality or speed.

By integrating their own automated warehouse picking solutions, a 3PL provider can significantly accelerate the picking process. For example, they can optimize warehouse layout to reduce travel time.

A 3PL provider can also offer insights into best practices that can improve efficiency. This can be especially valuable if you're looking to implement new processes or technologies.

By collaborating with a 3PL provider, you can leverage their expertise and resources to streamline your operations and achieve your business goals.

Discover more: 3pl Pick and Pack

24/7 Availability is a game-changer for businesses that need to operate around the clock. Automated systems can run smoothly 24/7, thanks to the automated picking and palletizing of a wide item and packing range.

This means that your operations won't be held back by traditional working hours. Separate picking warehouses for different temperature ranges, down to -30° C, can be implemented within the system, providing flexibility and control.

There are three main storage methods for cases to consider: you can evaluate each one individually and choose the best fit for your operations. You can also combine different types of storage depending on each product or picking method to optimize efficiency.

Single Order Picking is ideal for low to moderate volumes or diverse items, but it's less efficient for larger orders. This method handles each order individually, which can be time-consuming.

Batch Picking is a more efficient method for moderate to high-volume warehouses, where one picker handles multiple orders at once, grouped by factors like item proximity. This reduces travel time and improves efficiency.

Zone Picking is used in large, high-volume warehouses, where pickers are assigned to specific zones, and items are consolidated centrally, minimizing travel time. This method is particularly effective in large warehouses.

The Exotec Skypod system automates the entry and removal of cases from storage racks, making it easier to manage large volumes of cases. This system can help streamline your case picking operations.

Here are the key case picking methods summarized: