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 turover 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 limited 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.
In a competitive omnichannel fulfillment era where retailers are constantly trying to meet rising customer service levels, flexibility in order fulfillment processes and distribution operations is mandatory for survival. It means having the ability to continuously adapt to a dynamic mix of order profiles and proliferating SKU counts, while always maintaining a keen awareness of their impacts on fulfillment processes and inventory consumption. It means effectively balancing retail, wholesale and direct-to-consumer requirements. And it means being nimble enough to adapt and respond in real time to spikes in demand.
If you think this all sounds difficult to achieve, you're right. But to successfully navigate these omnichannel requirements, retailers need real strategies to enable this degree of flexibility. This was the focus of a recent On The Move webinar I moderated, titled "Addressing the needs for flexibility in current distribution operations." It's a holistic approach that encompasses facility design, picking and putting processes, and the importance of effective labor management. Following is a summary of the webinar's high-level points:
Profiling, slotting and facility design. It's important to design your distribution facility to not only meet today's demands, but also have the flexibility to adapt to future requirements. Warehouse profiling, which seeks to maximize space utilization by determining which types of slotting options are best-suited for particular products, is vital to fully utilizing available facility space and reducing replenishment costs. Well-profiled items make the most efficient use of shelf and rack space.
Picking technologies. The selection of picking technologies and methods, or some combination thereof, is an important operational decision that helps enable flexibility in the warehouse. While some technologies may provide increased flexibility, there may be trade-offs in productivity and costs. Retailers must weigh the pros and cons of these methodologies and select options that meet their operational objectives and order and inventory profiles.
Putting strategies. Putting refers to the processes that support order consolidation through the gathering of multiple, independent storage or picking areas into a single, shippable container. Minimizing worker travel and touches, and "golden zone" allocations to increase accuracy and throughput are all part of an effective putting strategy necessary for adapting to e-commerce and store replenishment requirements.
Labor management software. LMS helps retailers match resources to the day's expected demands while maximizing the efficiency of all tasks throughout the warehouse. Demand planning, execution monitoring, resource allocation and continuous performance improvements can be achieved with LMS - establishing both process predictability and the flexibility to move resources to adapt to variations in a given plan.
In short, DCs need not only to become more flexible in their slotting, picking and putting operations, but also in allocating labor resources to meet the demands of the day. For a more detailed explanation of each of these strategies, please visit our On The Move webinar archives and view my presentation in its entirety.
Omnichannel distribution center (DC) operators are always on the lookout for new order fulfillment technologies and seeking new ways to improve order accuracy and productivity. For many DCs, the problems they experience can be traced back to two primary issues:
1. Order fulfillment systems (including hardware and software) are not flexible enough to adapt to the varying order profiles, volumes and order filler workflows.
2. Order fulfillment processes are often disjointed, fragmented into several piecemeal systems that aren't easily coordinated into a unified operation.
These same DC operators are faced with ever-increasing consumer expectations. In a perfect world, they would also prefer a robust system capable of supporting complex order fulfillment processes that can also scale with fluctuations in demand. Intelligrated's flexible warehouse execution system (WES) adapts to these fluctuations with a proven suite of advanced fulfillment capabilities.
From pick- and put-to-light and Voice to RF scanning and mobile cart picking systems, Intelligrated offers comprehensive order fulfillment technologies that maximize warehouse productivity, speed and order accuracy.
- Pick and put-to-light systems - enable paperless, light-directed fulfillment with easy-to-read lights and displays
- Put-wall systems - provide goods-to-operator fulfillment for multi-line, mixed and single SKU orders
- Voice-directed picking - provides hands-free and eyes-up picking to facilitate fast fulfillment with extremely high order accuracy
- Mobile cart picking - combines pick-to-light, voice automation and RF technology to enable fulfillment of low-velocity items, enhanced mobility and go-anywhere flexibility
- RF handheld and mobile devices - support fulfillment of low-velocity items, providing favorable productivity gains over manual processes and, more importantly, real-time feedback of order filler progress
- WES software - automates the fulfillment processes within and beyond the four walls to drive maximum throughput and accuracy
As a single-source order fulfillment provider, Intelligrated fulfillment systems not only ensure maximum compatibility between software and hardware components, but also enable the integration of multiple technologies to accomplish complex tasks.
The broad range of PTL devices alone significantly increases the possibility of creating a solution that precisely meets DC requirements, including any or all of these scenarios: pallet, case and each picking; zone pick and pass or zoneless picking; and single multi-line batch picking for order consolidation. And as the manufacturer of the PTL hardware, Intelligrated can also develop custom PTL hardware as needed.
Perhaps Intelligrated's greatest strength is its proven experience and deep order fulfillment system expertise. This means you can be sure that we will develop an order fulfillment system that meets your DC's specific requirements and service level objectives. So if you're ready to realize the value of a true single source provider, contact us to begin a partnership with Intelligrated.