Tips for Improving Picking Operations - From Simple Fixes to Picking System Implementation

One of the crucial tasks in warehouse operations is picking. How smoothly shipping operations run often hinges on picking efficiency, yet it is also a task prone to a variety of challenges. What approaches are necessary to streamline picking operations? In this article, we delve into common problems encountered in picking and discuss points for improvement, as well as the implementation of picking systems.

Issues to Address Ahead of Implementing Major Improvements: Common Problems in Picking Operations

Picking errors occasionally occur during picking operations. Picking errors refer to incidents such as miscounting items or selecting the wrong items for shipment. The following are some specific cases where picking errors may occur:

① Picking using paper lists

Picking relying on paper lists is particularly prone to problems. In warehouses with numerous similar items, there is a constant risk of mistaking packages or item numbers. Even with thorough checking procedures in place, human error is inevitable in tasks performed by individuals.

② Problems before reaching the product shelves

In large warehouses or during high-volume orders, the time spent moving from product to product during picking (transit time) becomes a bottleneck. Inefficient routing due to poor shelf arrangements or narrow aisles hindering cart movement result in increasingly longer transit times. Moreover, longer transit times increase staff fatigue, reducing concentration and increasing the probability of human error.

③ Problems in finding products on shelves

Even after reaching the location of a product, it may actually take some time to find the intended item. A primary reason for items being hard to find is poorly defined product placement. In warehouses where only specific individuals know the locations of items, picking efficiency significantly suffers. Inadequate information in picking instructions also makes finding items challenging.

Points for Improving Picking Operations

After addressing any issues in the picking operations, here are some specific points for making improvements:

① Layout Enhancements

Preventing human error is essential to streamlining picking operations. However, reducing human error is not straightforward, regardless of how many verbal reminders are given to staff. While making efforts to raise awareness is not a bad idea, thinking about how to improve the warehouse environment is also worthwhile.

Product Layout
irstly, ensure precise placement of the merchandise on the shelves to eliminate situations where only specific individuals know where items are located. Additionally, consider revising the way items are located on the shelves. Place frequently retrieved items closer to the front of the shelf. While some warehouses group similar items on the same shelves, this can lead to increased picking errors. A better choice is to place similar items on well-separated shelves.

Shelf Layout
Aim to minimize routes by ensuring ample space between shelves. Improving layout reduces travel distance, which decreases transit times.

② Picking Instruction Optimization

Make picking instructions as easy to understand as possible. Instead of formats understandable only by veterans, aim for instructions that even novices can comprehend. Typically, picking instructions need only include the item number, quantity, and location. Simple instructions ensure consistent picking quality regardless of the staff member assigned.

Even simple adjustments, such as opening item containers or orienting them toward staff during item retrieval, can enhance picking efficiency.
Though these adjustments may slightly increase the time it takes to retrieve an item, they contribute to an overall time reduction in the picking operation.

③ Implementation of a Picking System

One way of streamlining picking operations is to implement a picking system. For complex picking operations involving numerous items and steps, new hires may require significant time to learn the job. Consequently, extensive training of new hires leads to high training costs.

Digital Picking Systems
To address such challenges, consider implementing a digital picking system. These systems use indicators mounted on the shelves to display necessary picking information, aiding staff in following instructions accurately. Digital systems ensure consistent work quality, even among novices.

Barcode-based Picking Systems
Barcode-based picking systems are also popular. With these systems, staff can accurately retrieve items without having to visually check a list, reducing the risk of picking errors. Additionally, these systems automatically count items. Simply scanning items as they are retrieved provides a precise count, even when faced with a cart stacked full of item boxes.

Efficient Picking Relies on an Optimized Work Environment
Picking heavily relies on manual labor and is prone to errors. Instead of solely relying on double-checking measures, reassess the warehouse environment to aim for efficient operation. Even small adjustments can dramatically improve work conditions. Moreover, with various digital tools available for picking, considering suitable options that meet your needs is definitely worthwhile.

Improving Operations Using Picking Carts

A number of points for improving picking operations, including simple fixes and the introduction of a picking system, have been presented. We hope you have found some hints for improving your operations. Consider implementing these improvements and introducing a picking system to help increase operational efficiency and reduce workforce requirements.

At Teraoka Seiko, we offer a variety of picking cart systems that can be seamlessly integrated into your existing work environment and facilities.
Please feel free to contact us for further information or a consultation.