Efficient warehouse picking is crucial for order fulfillment, constituting a significant portion of operating costs, often exceeding 50% in distribution centers. Addressing this labor-intensive task is paramount for streamlined operations. To enhance the order picking process, leveraging forklifts and warehouse pickers is indispensable, irrespective of warehouse size or product diversity.
These versatile lift trucks find applicability across various settings, tailoring their usage to the adopted order picking strategies. This guide delves into the significance of order picker equipment, elucidating the advantages it brings to warehouse operations.
What Are Order Picker?
Order pickers, whether individuals or specialized equipment, play a pivotal role in retrieving and delivering diverse items required for order fulfillment. These items are sourced from storage areas and subsequently directed to the shipping section. Operating at elevations surpassing a distribution center’s second racking level, order picker machines boast heights of up to 40 feet, effectively replacing conventional rolling ladders and pallet trucks.
Deployed in various warehouse scenarios, order pickers excel in both high-level and low-level picking, as well as very narrow aisle distribution centers. They prove particularly effective when dealing with processes involving the movement of numerous Stock Keeping Units (SKUs), where no single SKU comprises a high quantity of items. However, they are not the optimal choice for unit load picking, long-distance transportation, or right angle stacking.
Ensuring personnel safety is paramount, especially for those operating order pickers at elevated heights, necessitating the use of harnesses and comprehensive training on truck maneuvering. It’s crucial to recognize that there are four distinct types of order pickers available, each catering to specific warehouse sizes and the nature of items involved in the picking process. Choosing the most suitable order picker depends on the unique characteristics of your warehouse and the items being handled.
Types Of Order Pickers
There are two fundamental types of order pickers available for your facility: operator-up and mast-style order pickers. Operators commonly use order pickers to pick loose cases or items from pallets positioned at higher levels. These machines can handle weights ranging from low to medium, reaching up to 2,500 pounds and picking items at heights of 40 feet. Notably, the operator of this vehicle is situated on the same level as the inventory being picked.
On the other hand, mast-style order pickers are specifically designed for load lifting, featuring an elevation mechanism and fork in their mast structure. While capable of handling heavier loads compared to operator-up order pickers, they typically reach a maximum height of 12-20 feet, making them well-suited for low-level picking.
When choosing the most suitable order picker for your warehouse, it’s essential to consider the predominant level from which most items will be picked. Order pickers are often categorized into low-level, standard, and high-level pickers. Mast-style order pickers, focusing on low-level items, offer speed and ease of maneuvering. Conversely, if the need involves obtaining items from challenging, elevated positions, an operator-up order picker may be the more suitable option.
Types Of Order Pickers Available
Semi Electric Aerial Order Picker
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Task Support Vehicle
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Picking Strategies
There are four distinct picking strategies to consider for optimizing warehouse operations:
Batch Picking
- Â Involves pickers moving across the warehouse to fulfill multiple orders with the same SKU.
- Pickers select a group of different orders simultaneously, streamlining the process and reducing the need for multiple trips to gather items for different orders.
Zone Picking
- Â Follows a “pick and pass” strategy, commonly used for multi-item or complex orders.
- Specific zones assign pickers to similar SKUs organized into defined zones.
- To complete an order, pickers exclusively select the necessary SKUs from the assigned zone, enhancing efficiency.
Wave Picking
- Entails fulfilling orders by selecting a single SKU at a time.
- Optimizes shipping and picking operations by scheduling order picking at different times throughout the day.
Cluster Picking
- Allows personnel to pick items for multiple orders simultaneously by placing them into pick clusters.
- Â Pickers can fulfill orders in a single trip to the pick location, making this strategy particularly effective for small order picking.
When deciding on the most suitable picking strategy, it’s crucial to consider factors such as the size of the facility, order volume, SKU diversity, and the availability of human and financial resources. Each strategy addresses specific operational needs, and selecting the right one can significantly enhance warehouse efficiency.
Order Picker Roles And Responsibilities
When selecting order picker equipment for your warehouse or distribution center, prioritizing operator safety and ensuring proper training for employees using these vehicles is paramount. Even with inherently safer low-level pickers, the potential for injury or product damage exists, underscoring the critical need for comprehensive training. Personal protective equipment is a non-negotiable requirement for anyone operating a picker.
Regular inspection and maintenance of the equipment are essential not only to reduce repair costs but also to uphold personnel safety. Neglected maintenance increases the risk of malfunctions during operation, making routine inspections crucial for early issue detection and preventing substantial expenses on extensive repairs.
Embracing technology is indispensable for modern warehouses aiming to enhance efficiency and sustain productivity. Equipping your pickers with the knowledge of utilizing Warehouse Management Systems (WMS) and other technological tools streamlines the picking process, contributing to a more efficient and organized workflow.
Additionally, hiring skilled and trained operators further facilitates the achievement of productivity goals. Well-trained operators not only minimize the likelihood of accidents but also contribute to the efficient completion of the picking process. Prioritizing safety, training, maintenance, and technological integration collectively fortify your warehouse operations for optimal productivity.
Automation In Order Picking
Exploring automation technologies can significantly enhance the efficiency of the picking process in your warehouse. If you’re seeking solutions to boost productivity, autonomous mobile robots (AMRs) stand out as a compelling option. These robots excel in transporting items autonomously, eliminating the need for preset paths or constant supervision by employees.
AMRs distinguish themselves by their ability to choose the shortest and most efficient route while intelligently avoiding collisions with both moving and fixed objects. While other automation technologies exist, AMRs offer an unparalleled level of flexibility, ensuring optimal route selection for safety and efficiency.
Please note that designers have seamlessly designed these technologies to complement the work performed by human pickers.
The implementation of AMRs translates into tangible benefits such as shorter picking routes and reduced walking time. Automation proves versatile across various industries, including medical equipment, eCommerce, retail, transportation, and manufacturing. Opting for automation eliminates the reliance on bulkier and less flexible conveyors for the picking process. Beyond the immediate gains in efficiency, automated warehouse picking mitigates the risk of inefficient tracking, human errors, and delays, offering a more streamlined and reliable operation.
Conclusion
Irrespective of the warehouse or distribution center you oversee, integrating order pickers into your material handling operation is highly advisable for efficient order fulfillment. Select order picker equipment and choose a picking strategy based on factors such as budget, desired features, the nature of handled items, and the height at which these items are stored.
In the realm of picking operations, ensuring that all personnel involved undergo thorough training is crucial for maintaining a safe worksite. Employing automation and leveraging technology can further enhance safety and efficiency in your picking processes. Looking ahead, the evolution of artificial intelligence and machine learning holds promise for advancements in order picking equipment. Ongoing developments in these areas promise to deliver even more improved outcomes, despite the proven effectiveness of autonomous mobile robots.
For further insights or to discuss your unique requirements, we invite you to connect with us Explore the unparalleled expertise and quality solutions that Shabbir Enterprises brings to the table, ensuring your material handling needs are met with precision and reliability
