Optimize your picking processes and maximize warehouse performance. Discover proven strategies and smart solutions from proLogistik here.
To maximize warehouse performance during picking, companies should switch to paperless, system-supported processes. This transition can reduce picking times by up to 30% and lower error rates by 20%. Intelligent picking strategies and optimized travel paths play a vital role in this. Seamless software integration, such as a Warehouse Management System (WMS), is crucial. Companies that digitalize their intralogistics do not just increase their throughput; they also reduce long-term process costs by up to 15%.
The Most Effective Strategies for Increasing Performance
To make picking more efficient, physical processes and the controlling software must mesh perfectly. Here are the most important levers:
1. Paperless Picking
Eliminating printed pick lists is the fastest way to gain efficiency. With mobile data entry (MDE) devices, Pick-by-Voice, or Pick-by-Light, orders are transmitted directly to employees.
- Advantages: No paperwork, real-time booking in the system, drastic reduction of picking errors. Studies show that picking errors can be reduced by up to 30%.
2. Intelligent Picking Strategies
Depending on the order structure, different methods are suitable for minimizing travel distances:
- Multi-Order Picking: Several orders are collected simultaneously on one picking cart. This is ideal for E-commerce, where hundreds of orders must be processed daily.
- Zone Picking: The warehouse is divided into zones. Employees only pick in their assigned area, which can increase efficiency in large warehouses by up to 20%.
- Goods-to-Person: Automated systems, such as shuttle warehouses, bring items directly to the picking station. This can increase productivity by up to 50%.
3. Warehouse Layout and Slotting
The arrangement of items in the warehouse (slotting) has a massive impact on performance. Fast-movers (A-items) should be easily accessible and placed close to the goods-out area, while C-items are stored further back. Restructuring the warehouse can shorten picking time by up to 15%.
System Comparison: Manual vs. System-Supported
Switching to a modern Warehouse Management System (WMS) offers significant advantages over traditional methods. According to a study by the Fraunhofer Institute for Material Flow and Logistics, the error rate in WMS-supported picking drops to below 0.1%, while it lies between 1% and 3% for manual picking.
| Criterion | Manual Picking (Paper) | System-Supported Picking (WMS) |
| Error Rate | High (approx. 1-3%) | Very low (< 0.1%) |
| Travel Paths | Often unstructured and long | Path-optimized via algorithms |
| Inventory Transparency | Time-delayed (after manual entry) | Real-time (immediate booking) |
| Onboarding Time | Long (warehouse knowledge required) | Short (system guides the employee) |
| Scalability | Low (quickly reaches capacity limits) | High (easily adjustable) |
The Role of Software: The pLG WMS
For optimal warehouse performance, powerful software is decisive. With the pLG WMS, the proLogistik Group has created a solution that supports companies in the digital transformation of their supply chains. Our logistical solutions are “Made in Germany” and offer comprehensive functions.
The system goes far beyond simple picking and offers the following advantages:
- Path Optimization: The WMS efficiently calculates the shortest routes through the warehouse, significantly increasing productivity.
- pLG Pick & Pack: Enables picking directly into the shipping carton—including intelligent volume calculation—saving a complete work step at the packing station.
- Seamless Integration: The pLG WMS integrates smoothly into existing ERP systems and E-commerce platforms, ensuring consistent and scalable processes in multi-channel sales.
With a combination of our software and suitable hardware like MDE devices or voice systems, we offer a comprehensive solution. Companies benefit from up to 30% faster order processing and a reduction in error rates by up to 50%, leading to a significant increase in efficiency.
FAQ: Frequently Asked Questions about Picking Optimization
How can paperless picking shorten picking times? Paperless picking eliminates the need to read lists, check them off, or manually enter data into the system. Employees are efficiently guided to the next item, and confirmation occurs in split seconds via scan or voice input. In one study, picking time was reduced by up to 30%.
How does a WMS integrate seamlessly into existing ERP systems? Modern WMS solutions like pLG WMS offer standardized interfaces (APIs). These enable the real-time exchange of order data, inventory, and article master data between the ERP system and the warehouse. A practical example shows that companies were able to shorten their data processing times by up to 50% through this integration.
What are the best strategies for multi-order picking in E-commerce warehouses? Path-optimized batch picking is particularly effective here. The WMS groups several small orders into one “batch.” A picker collects all items on a multi-order cart and sorts them directly into the corresponding customer compartments or shipping boxes. In one E-commerce warehouse, efficiency was increased by 25% using this method.
To improve picking and warehouse performance, digitalization with system-supported processes is crucial. The use of paperless technologies and intelligent picking strategies in conjunction with a powerful WMS like the pLG WMS reduces travel distances and minimizes errors. This increases efficiency and makes the warehouse fit for the future.
Take advantage of digitalization to bring your warehouse to the next level. Contact us today for a consultation.