Case Picking Meaning and Optimization Techniques

Case picking is a crucial aspect of warehouse operations, and understanding its meaning and optimization techniques is essential for efficient order fulfillment.

The goal of case picking is to quickly and accurately select cases of products from a warehouse to fulfill customer orders, with the average warehouse picking 30,000 to 50,000 cases per day.

Effective case picking requires a combination of strategic planning, efficient workflows, and well-designed storage layouts to minimize travel time and maximize picking speed.

A well-designed storage layout can reduce travel distances by up to 50% and increase picking speeds by up to 30%.

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Case picking is a method of picking products from a warehouse where items are stored in cases, rather than individual units.

In a case picking system, products are stored in cases and then picked by order, making it a more efficient way to fulfill orders.

A case typically contains multiple units of the same product, which can range from 6 to 48 units, depending on the product and the warehouse layout.

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This method is often used in warehouses that handle a high volume of orders, as it allows for faster and more accurate picking.

The key benefit of case picking is that it reduces the number of picks per order, making the picking process faster and more efficient.

By picking cases instead of individual units, warehouses can also reduce the number of stock locations and the complexity of the picking process.

In a case picking system, the warehouse layout is designed to optimize the picking process, with cases stored in a way that minimizes travel time and maximizes efficiency.

This approach requires careful planning and design to ensure that the warehouse layout is optimized for case picking.

Overall, case picking is a highly efficient method of picking products from a warehouse, particularly in high-volume order environments.

Case picking offers several key benefits that can significantly enhance warehouse operations. By allowing warehouse employees to manage multiple items in a single motion, case picking boosts warehouse picking productivity.

This method significantly speeds up the order fulfillment process, as pickers move less frequently between individual items. The result is a reduction in labor costs by reducing the time spent on each pick.

Case picking also reduces storage space per item, allowing warehouses to better utilize vertical and horizontal space. This compact storage method reduces the footprint needed for inventory, allowing for more items to be stored in the same amount of space.

By storing and picking cases rather than individual SKUs, warehouses can improve the organization and accessibility of goods. This leads to substantial savings per unit, making operations more cost-effective and enhancing profitability.

Here are the key benefits of case picking:

There are three different types of storage methods for cases, each with its own advantages and disadvantages.

Pallet storage is the most common and efficient method, allowing for the highest-density storage and pick rate per hour.

Rack shelf storage is another common method, but it may require more labor costs since cases need to be moved from pallets to shelves.

Choosing the right storage method depends on the characteristics of each item, such as size, weight, and demand frequency.

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Pallet storage is a common and efficient method for storing case picking operations. This involves stacking cartons on top of each other either on the floor or on a rack, allowing for the highest-density storage.

This method allows for the highest pick rate per hour or lowest time per pick in case picking operations. In fact, pallet storage is considered the highest-density storage in general for case picking operations.

Pallet storage is ideal for warehouses with high-volume orders or bulk shipments, as it enables quick movement using forklifts. This is especially useful for large bulk orders, such as wholesale restocking.

By using pallet storage, warehouses can optimize their storage space and increase productivity. This is because pallets can be easily stacked and retrieved, making it easier to manage inventory.

Here's a comparison of pallet storage with other storage methods:

Overall, pallet storage is a practical and efficient solution for warehouses with high-volume orders or bulk shipments.

Rack Shelf Storage is a common way to manage case storage, but it's not as efficient as standard pallet storage. It's often used by businesses with a high number of SKUs and lower overall quantity of cases per SKU.

Storing cartons on shelves allows for placing them at waist level, which can be beneficial for businesses with a lot of SKUs. This can lead to faster picking times and improved productivity.

Rack shelf storage can require more labor costs because cases need to be moved from pallets onto shelves. This can be a challenge, especially for businesses with a high volume of cases.

By using rack shelf storage for high-volume items, businesses can improve picking efficiency and maximize space. This is especially useful for items with large order volumes.

Optimizing Operations is crucial to streamline case picking processes. Clear, consistent labeling helps pickers quickly identify the correct cases.

Efficient packaging reduces the need for repacking or adjusting cases during the picking process. This speeds up operations and enhances order accuracy and customer satisfaction.

Implementing a dedicated case picking area can significantly boost efficiency, especially for larger orders or products ordered in full case quantities. The layout and organization of this area are vital for ease of access to different products.

Barcode scanners and RF technology can also optimize case picking by reducing manual input and keeping order status updated in real-time. This helps improve accuracy and increases picks per hour.

Implementing case picking in a warehouse involves setting up a dedicated area specifically for this purpose, where cases are stored on pallets for efficient access and sorting.

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

The Exotec Skypod system boosts throughput up to 5x compared to manual methods, with the ability to retrieve any case within two minutes.

To optimize case picking, consider incorporating barcode scanners and RF technology to reduce the time required to input transactions into the WMS or other database.

Barcode scanners and RF technology help optimize case picking by reducing the time required to input transactions into the WMS or other database, keeping the status of orders updated in real-time.

A Warehouse Management System (WMS) enables the automation of processes such as creating pick lists and enabling order picking according to different types of methods, including zone picking, wave picking, and batch picking.

Here are some key benefits of implementing a WMS:

By combining AutoStore's automated picking capabilities with traditional case picking, warehouses can achieve a high level of efficiency and flexibility, ensuring that whether an order requires individual items or full cases, the warehouse is equipped to handle it in the most efficient way possible with warehouse automation.

Case picking optimizes bulk order fulfillment, but certain scenarios demand the flexibility of handling smaller quantities or individual items, where split-case picking comes into play, selecting items in quantities less than a full case, typically for direct-to-customer (DTC), business-to-business (B2B), and store replenishment orders.

Ergonomics plays a significant role in optimizing operations, especially in order picking methods that involve picking items from high or low areas.

Improving ergonomics can help reduce the potential for injury and increase productivity. This is particularly important for case picking, as cases are generally heavier and can be difficult to handle.

Placing shelving no lower than waist level can help alleviate strain on workers. This simple adjustment can make a big difference in reducing fatigue and improving overall efficiency.

Equipment such as a lift table for pallet storage can also be a game-changer in improving ergonomics. By reducing the need to lift heavy pallets, workers can focus on more productive tasks.

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

This method involves stacking cartons on top of each other on the floor or on a rack, making it easy for warehouse pickers to retrieve them.

Choose the most efficient storage method based on the characteristics of each item, such as size, weight, and demand frequency.

For high-demand items, consider using fixed location storage to quickly locate and retrieve them.

Dynamic or random location storage is suitable for lower-demand items, allowing for maximum space utilization and improved picking efficiency.

Pallet storage also enables the lowest time per pick in case picking operations, making it a valuable option for warehouses.

Choosing a storage method is crucial for efficient case picking operations. The most common and efficient method of storage is by pallet, which allows for the highest-density storage and the highest pick rate per hour.

Pallet storage is ideal for case picking operations, but you may want to consider selecting a storage type for each item based on its characteristics. This way, higher volume items can use carton flow or rack shelf methods, while slower-moving items can benefit from regular pallet storage.

In a warehouse with diverse items, single order picking is often the most efficient method. However, for larger orders, batch picking or zone picking may be more effective in reducing travel time and improving efficiency.

Here are some key order case picking methods to consider:

Automated storage systems, such as the Exotec Skypod, can also be used to optimize storage and retrieval operations.

Manual case picking is a hands-on process where warehouse staff physically collect cases from shelves, racks, or pallets.

It's labor-intensive, relying on physical exertion from workers to retrieve cases, leading to fatigue and potential injuries.

Manual case picking poses a risk of errors, as manual handling increases the likelihood of picking the wrong cases or quantities.

Automated case picking utilizes machines or robotics to retrieve and handle cases of products, reducing the need for manual labor.

This method improves efficiency, accuracy, and speed by automating the selection, transportation, and sorting of cases.

Manual case picking is a flexible method that can adapt quickly to changes in inventory or order types without the need for reprogramming or system adjustments.

It requires less upfront investment compared to installing automated systems, making it a lower-cost option for businesses.

Manual picking allows for human judgment in handling delicate or irregularly shaped items, potentially reducing damage during the picking process.

Here are some key benefits of manual case picking:

Other automated systems, such as robots or selective conveyor systems, can greatly increase the efficiency of your case pick activities. These systems have an upfront operation expense, but over time can reduce the cost and time per pick for your case pick operations.

They can operate continuously, eliminating breaks and fatigue, which significantly boosts productivity. This means you can get more done in less time, and with less strain on your employees.

The use of automated systems can also reduce the risk of human error, ensuring that orders are accurately picked, and inventory levels are accurately maintained. This is because automation reduces the risk of mistakes made by humans.

In high-volume environments, implementing automated solutions into your warehouse can be highly beneficial. It can help you keep up with the demand and reduce the need for manual labor.

Here are some key benefits of using automated systems:

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

Automated systems can reduce the risk of human error, ensuring that orders are accurately picked, and inventory levels are accurately maintained. This consistency and accuracy are crucial for warehouses that handle a high volume of orders.

Automated case picking can significantly reduce the need for manual labor, decreasing overall labor costs. This can be a huge cost savings for warehouses that rely heavily on manual labor.

Here are some key benefits of automated case picking:

By implementing automated case picking, warehouses can achieve a high level of efficiency and flexibility. This approach ensures that whether an order requires individual items or full cases, the warehouse is equipped to handle it in the most efficient way possible with warehouse automation.

A Warehouse Management System (WMS) is a game-changer for case picking operations, enabling the automation of processes like creating pick lists and order picking.

This system allows pickers to be assigned multiple orders or any number of orders, rather than a single order, according to an algorithm that determines the most efficient way to schedule workers.

Automating these processes can significantly increase productivity in warehouse operations.

A WMS can consolidate orders, ensuring that items picked individually from an AutoStore system are effectively combined with full cases picked from external storage.

This is particularly useful when integrating AutoStore with case picking strategies, as it allows for a seamless order fulfillment process catering to both single-item and bulk orders.

By combining these two systems, warehouses can achieve a high level of efficiency and flexibility in handling orders.

Automating your picking process can significantly reduce or even eliminate mispicks, while enhancing speed and accuracy.

Modula's range of solutions, including Put to Light systems and automated storage and retrieval systems, can boost efficiency across your warehouse operations.

Case picking is inherently more efficient than piece picking, as each pick moves a larger quantity of product.

Handling orders that naturally align with case quantities can reduce the need for breaking down cases into individual items.

Retail industry is a prime candidate for case picking, particularly for distribution centers that supply stores. These centers use case picking to replenish store inventories efficiently.

The retail industry's bulk and repetitive orders make case picking a suitable choice for quick and streamlined inventory management. This method ensures that products are shipped in entire cases, meeting the industry's needs.

Distribution centers can benefit from case picking, as it helps them manage inventory more efficiently. This, in turn, can lead to cost savings and improved customer satisfaction.