Put walls play an increasingly vital role as a growing number of distribution centers (DCs) take on the challenges of fulfilling e-commerce and direct-to-consumer (DTC) orders. By providing an effective way to consolidate diverse products across multiple channels within a DC, put walls make it easy to enhance efficiencies, especially when integrating manual and automated picking workflows with enabling technologies.
Simple concept, dramatic results
A put wall is a cabinet-like structure divided into a series of compartments or "cubbies." One side is typically staffed by one or more operators who put product into assigned cubbies for their respective orders. On the other side, operators pack out the orders or place them on a takeaway conveyor that whisks them off to shipping.
Where and how put walls are integrated into the workflow can vary widely, depending on the operation. The basic idea is to consolidate demand from various upstream picking processes into the appropriate cubby. This enables efficient multichannel fulfillment of both mixed- and single-SKU orders, making put walls ideal for DCs that handle multi-line orders with regular promotions, flash sales or seasonal specials.
What's driving put wall adoption?
As consumer expectation and the number of online orders continue to rise, the pressure is on retailers to address several significant challenges:
SKU proliferation - Consumers continue to buy more online, and even infrequently ordered items must still be accounted for in the fulfillment process. Put walls make it possible for DCs to optimize upstream picking processes and take on more SKUs, while still maintaining accurate and efficient order consolidation and pack-out processes.
Changing order and product profiles - From small to large products to orders of widely varying sizes, product and order profiles are dictating ever more flexible order processing and handling requirements. The newest generation of configurable put wall technology offers a ground-breaking shift from fixed to customizable cubby sizes, delivering slotting gains of up to 35 percent just by optimizing existing rack space.
Omnichannel diversification - To keep up with the demands of omnichannel fulfillment, many retailers are converting their existing facilities to incorporate e-commerce distribution into their supply chain operations. Retailers are integrating put walls to deal with these complexities, reduce order errors and increase throughput.
Enabling technologies enhance put wall efficiency
Put walls can be enhanced by technologies that direct the operator to place items in the correct cubby, then confirm when an order is complete. These enabling technologies - including radio frequency (RF) scanners, and voice- and light-directed systems - deliver return on investment relatively quickly by significantly improving operator productivity and order accuracy.
In picking and putting scenarios, these technologies enable intelligent order batching, adjustments and order allocation among wave, pick and put. Built-in slotting logic also provides ergonomic benefits to pickers, minimizing fatigue by keeping as much movement as possible inside the "golden" zone.
To learn more about put wall solutions and the enabling technologies that enhance them, click here.
Accuracy plays a critical role in the success of any modern distribution center (DC). In fact, for some businesses such as pharmaceuticals, accuracy outweighs every other aspect of the DC, including cost. No matter what the product, accuracy can help to build a loyal client base, while even one incorrect pick can cost you a valuable customer.
Yet as crucial as it is to any business, ensuring order accuracy has become an even bigger challenge as the complexities of omnichannel fulfillment have multiplied in recent years. To make matters worse, many pick- and put-to-light systems aren't designed with the ability to assist pickers in making sure every order is accurate. Too often, order fillers can't even ask the system basic questions about SKU numbers or order IDs, while managers can't easily trace errors to particular workers.
Here are four key ways modern pick-to-light systems give pickers and DC managers the tools they need to ensure order accuracy:
1. Empowering pickers - Order fillers can query the system to determine the correct SKU, order ID, store ID and last put location. They can also report important conditions back to the system, such as out-of-stock items, damaged merchandise or requests to suspend stock locations.
2. Management insight - Managers investigating the sources of order inaccuracies can trace errors back to specific order fillers. Labor locations, pick rates and accuracy rates are available 24/7 via virtually any type of digital display device, from smartphones to tablets and laptops. This gives managers the ability to find the sources of any problems through labor management software and, if necessary, provide additional coaching or training to individual order fillers.
3. Checking the weight - For an additional quality measure, Intelligrated's pick-to-light systems can perform a weight check, comparing an order's actual weight to its expected weight. This simple step can identify mismatches before an order is shipped to the buyer, giving the DC a valuable backup strategy to ensure the order is correct.
4. Adapting to variable product sizes - Modern pick-to-light systems include trays designed to accurately handle a wide variety of product sizes and shapes, increasing picking and putting accuracy in high-velocity, high-SKU omnichannel and e-commerce fulfillment environments. This allows retailers to optimize shelving and racking allocations to accommodate different product profiles throughout the year, always keeping relevant items within a picker's reach.
Whether your business is focused on e-commerce, store replenishment, retail, omnichannel fulfillment, manufacturing or route distribution, advanced pick- and put-to-light technology provides scalable, flexible solutions that drive maximum throughput and order accuracy. To learn more about how Intelligrated's intelligent pick-to-light systems can make your DC's fulfillment more accurate, click here.
While pick-to-light systems have been used for three decades or so, today's distribution centers (DCs) face omnichannel pressures that didn't exist when they were first introduced. In addition to the needs of traditional store fulfillment, DCs also face the challenges of e-commerce, including a growing number of SKUs, seasonal demand peaks and the high expectations of service level agreements (SLAs).
Unfortunately, most pick-to-light systems available today don't take advantage of abundant opportunities to improve productivity throughout the distribution chain. What's worse, some systems can't cope with the rigors that seasonal surges and other demand spikes place on picking processes - even to the point of failure.
Here are nine ways modern pick-to-light systems are keeping pace with today's fulfillment challenges - and anticipating the future:
1. Higher-volume picking - Modern pick-to-light systems are the industry's gold standard, increasing productivity rates by up to 50 percent compared to traditional paper systems. That's double the gain offered by voice and radio frequency (RF) systems, which average around 25 percent.
2. Less training time - Today's pick-to-light technology is intuitive and easy to learn. This reduces the need for extended training, while making it easier to manage turnover and maintain flexibility in your labor force.
3. Flexible technology - Many pick-to-light systems can't adapt to rapidly changing order profiles, volume or picker workflows. Intelligrated offers the industry's most comprehensive hardware options to meet any DC's unique requirements.
4. Dynamic shelf space optimization - Intelligrated's xD (extended display) ensures proper picking and slotting size, adapts to smaller SKUs, eliminates un-utilized shelf space and saves order fillers unnecessary walk times.
5. Full system integration - Warehouse execution software (WES) software enables the seamless integration of pick-to-light with a wide variety of hardware, technologies and systems. This also makes it easy to respond quickly to hot or accelerated orders, which traditional systems often struggle with.
6. Live monitoring and predictive planning - Real-time data allows DC managers to track individual work or zone productivity while optimizing throughput and responding to daily demand fluctuations. Historical data is used to properly allocate your workforce, evaluate shift structuring and look for new ways to maximize productivity.
7. Easy troubleshooting - Onboard diagnostics report events in real time while generating a "stay alive" heartbeat signal, allowing problems to be pinpointed and resolved quickly.
8. Hardware durability - From pick faces built from aluminum or high-impact polycarbonate, to anti-vibration connectors and strict "burn-in" testing, modern pick-to-light components are designed to withstand the abuse of day-to-day warehouse environments.
9. Bypass options - Backup options allow order fillers to keep working, even if a pick-to-light hardware component fails. The system software adapts immediately to prevent large-scale disruptions, often limiting outages to a single shelf. In the meantime, pickers can get the information they need from a separate display, RF device or voice system.
The tight integration of Intelligrated's pick-to-light hardware and software enables optimum workflow and simple scalability, offering your business a competitive advantage.
The challenge of delivering e-commerce, direct-to-consumer orders has introduced new levels of complexity in fulfillment centers. Wide variances in order profiles, the proliferation of SKUs and items with varying pick velocities are all highlighting the importance of effective order consolidation processes. Although many fulfillment centers are deploying automated systems in strategic areas of the facility to improve picking, sortation and putting efficiencies, order consolidation - which requires an effective way to aggregate this demand from disparate areas of the facility - often suffers. Regardless of the picking and sortation method used, put walls are becoming an indispensable tool for adapting to modern fulfillment demands and providing efficient order consolidation.
The premise behind put wall utilization is to bring together items gathered from disparate picking activities into one place. By consolidating this demand at one or more put walls throughout the facility, fulfillment centers see efficiency gains in upstream picking processes and, more importantly, increases in order fulfillment throughput and accuracy.
Traditional put walls are designed with fixed compartment sizes (or cubbies) and typically rely on lights, voice or RF technology to automate the confirmation process as an operator puts items into cubbies for specific orders. While effective, these fixed put wall designs may limit a retailer's ability to adapt these cubby sizes in response to changing order and product profiles, thus resulting in poor space utilization in the warehouse. The recent introduction of modular put wall designs, which allow the warehouse manager to change the configuration of cubby sizes (hardware) and light confirmation sequences (software) - provides the flexibility and space utilization that high-density fulfillment centers demand.
Our next On The Move webinar, titled, "Concerns about changing order profiles? 'Put' them to rest!" will explore these concepts and the increasing use of put walls in omnichannel fulfillment centers. The webinar will take place on Thursday, April 27, 2 p.m. EDT / 11 a.m. PDT, and be presented by Doug Mefford, product manager for order fulfillment with Intelligrated Software. With two decades of hands-on experience in driving throughput and accuracy in warehouse workflows and automation technologies, Doug will explain how put walls are improving order fulfillment productivity. Attendees will learn:
- The emerging role of the put wall and its order consolidation benefits
- Several key scenarios where put walls are effective
- How to recognize when order volume thresholds warrant put wall integration
- Why the need for flexibility led to new put wall hardware and software that enables user-driven customization
To learn more about put wall best practices and tips for integrating them in order fulfillment operations, register now for our upcoming On The Move webinar on Thursday, April 27, 2 p.m. EDT / 11 a.m. PDT.
The rapid growth of e-commerce and rising consumer expectations are prompting retailers to adjust their order fulfillment strategies to keep up with these demands. Luckily, several enabling technologies are coming of age which allow retailers to respond accordingly.
Here's a quick overview of the most effective strategies and solutions currently available, which can be combined and integrated in multiple ways to meet any fulfillment operation's unique needs.
Enhance picking productivity
Many DCs have already made the shift to paperless picking solutions, which increase productivity by up to 50 percent. Depending on your business needs, productivity can be enhanced with one or more of the following:
Pick-to-light - These scalable, easy-to-use systems combine intuitive colored displays that guide the pick with sophisticated algorithms that reduce movement times and accommodate hot picks. Minimal training is required, and built-in diagnostics enable easy troubleshooting - making pick-to-light the industry's most efficient, accurate and high-speed order fulfillment solution.
Put-to-light - Similar to pick-to-light, put-to-light solutions direct pickers to the correct bin or slot to place an item. Best suited for batch-picking applications, put-to-light brings comparable improvements to accuracy and productivity when compared to traditional manual sorting.
Voice picking - This solution provides voice commands via a wireless network, leaving the picker's hands free while increasing picking speed and accuracy rates. Voice commands can also be programmed in multiple languages, significantly decreasing training requirements for non-English speakers. Voice picking can be used as a cost-effective, stand-alone system or as a fully integrated enhancement of other solutions.
Radio frequency (RF) technology - Handheld and mobile RF devices are ideal for lower-velocity SKUs, enabling 99.9 percent accuracy and increasing productivity by 10 to 15 percent.
Mobile picking carts - For low-velocity applications, mobile cart systems combine advanced pick-to-light components, voice automation and RF scanners in a system with go-anywhere flexibility.
Improve omnichannel distribution with put walls
Whether DCs rely on operator-to-goods batch picking, disparate zone-picking processes, or an automated storage and retrieval system (AS/RS), put walls maximize efficiency by serving as points of demand consolidation. Ideal for multi-line orders, flash sales or seasonal demand, put walls save time and labor by enabling intelligent order batching, adjustments and other allocations among wave, pick and put.
Automate for efficiency
Respond to ever-changing business needs quickly while minimizing labor with intelligent automation solutions:
Warehouse execution systems (WES) - WES software optimizes your facility with an operational brain, delivering real-time responsiveness with automated decisions based on constant analysis of orders, inventory, labor, processes and equipment.
Automated storage and retrieval solutions - Ideal for operations with high-turn inventory storage and short order cycles, AS/RS systems provide quick access to products, while reducing storage labor and footprint requirements.
Unit sortation - Designed for ultra-light, irregularly shaped and polybagged items, these systems deliver the highest throughput at minimum speeds for years of reliable, low-maintenance operation.
Intelligrated is an experienced designer, manufacturer and installer of all these solutions. To learn more about order fulfillment systems that can save you time, money and hassles, click here.