Have you ever felt that no matter how hard you try to optimize your warehouse, order picking errors keep popping up? You are not alone. This seemingly invisible but critical process consumes between 45% and 75% of your warehouse's operational resources. We are talking about picking, that vital bridge that connects the promise you make to your customers with the experience they live.
In these times of ultra-fast deliveries, perfecting picking is an operational improvement, it's also your lifeline in an unforgiving market. Are you ready to discover how to take your picking accuracy to the next level? Join us in this guide!
The hidden side of logistics success: picking and its impact
When we think of picking, it goes beyond taking products off a shelf. It's a meticulous art where every move counts: picking, grouping and preparing those small loads that, together, will make your customer happy. The way you execute this process defines when the order arrives, in what condition, and whether it contains exactly what was ordered.
María Jiménez, an operations supervisor who implemented a new picking system, shares her experience: "I couldn't believe it. In just three months, we reduced picking errors by 87%. The best thing was to see our positive ratings go up by 23%. Customers noticed it immediately.
With the e-commerce boom, the pressure on this process has multiplied. The National Commission for Markets and Competition (CNMC) reported that in just one quarter of 2020, Spain moved 258.9 million online transactions and €12.8 billion. Can you imagine how many pickings are behind those numbers? (Blog - Solistica)
Mistakes that sabotage your picking system (and how to overcome them)
Although zero error is nearly impossible, identifying and correcting the most common failures can bring us closer to that ideal. Here are the top problems affecting your operation:
- Wrong picking: A misplaced item leads to picking the wrong product, generating complaints and eroding customer confidence. Solution: Implement a clear bin system and scanning technology for verification.
- Quantity trap: Picking incorrect quantities generates sloppy inventories and dissatisfied customers. Solution: Use bar code scanners that clearly indicate quantities and record each operation.
- Similar identifiers: Similar references (A-1001 vs. A-1010) cause confusion, especially under time pressure. Solution: Implement powerful visual signage and technologies such as pick-to-light or voice picking.}
- Product dispersion: Having the same product in different locations is time-consuming and increases the risk of errors. Solution: Reorganize according to principles such as ABC analysis and maintain rigorous stock management.
Other culprits include unlabeled products, commingling of orders, unauthorized replacement of items, and picking with wrong dimensions. (Blog - Solistica)
Technology: your best ally for a smooth picking process
The difference between average picking and exceptional picking usually has a clear name: technology. Evolution in this field has radically changed what is possible to achieve, turning once manually tedious processes into accurate and efficient systems.
Systems that are revolutionizing order picking
- Warehouse Management Systems (WMS): Visualize having a digital brain that coordinates every movement in your warehouse, from receiving to shipping. A good WMS plans the most efficient picking routes, additionally it gives you real-time visibility of where each product is.
Automatic recognition technologies:
- Pick-to-light: LED lights that illuminate exactly where your prepper should go. Simple but incredibly effective.
- Voice picking: Voice prompts allow your team to work hands-free and eyes-free. Multitasking taken to another level.
- Barcode scanning: Your safety net to ensure that every product is exactly as it should be.
- AGV (Automatic Guided Vehicle): Intelligent forklifts that move autonomously, like tireless assistants.
- Automated structures: Cabinets that optimize space and facilitate scanning.
- Automated rails: Like internal highways that connect different areas of your warehouse.
Carlos Rodriguez, operations manager who transformed his distribution center, shares his experience: "At first I was skeptical about voice picking, but the results left us speechless. We reduced picking times by 30% and our accuracy went up to 99.8%. We virtually took human error out of the equation." (Blog - Solistica)
The four key steps to picking that never fails
Did you know that picking can be divided into four critical stages? Mastering each of them is critical to creating a mistake-proof system:
- Pre-planning: Allocate the right resources before starting. A good Warehouse Management System (WMS) automatically identifies the optimal combination of human and material resources for each operation.
- Route design: Movements consume time and energy. Depending on your method (batches, waves, or zones), design routes that minimize unnecessary movements and optimize each trip.
- Extraction: Adapt your strategy according to the location of the product (ground level, low height, medium or high level). Having the right tools for each situation is essential to maintain efficiency.
- Verification: A thorough final check of units and weight is your best insurance against claims. This final filter ensures accuracy before shipment. (Blog - Solistica)
Picking methods: finding the perfect system for your reality.
There is no universal picking method. The key is to select the one that best suits your reality:
According to direction of goods:
- Man-Product: Operators roam the warehouse. Lower initial investment but more time.
- Product-Man: The goods reach the operator through automation. Higher investment, ideal for large volumes.
According to pick-up:
- Order to order: Each operator focused on a single order.
- Order waves: Simultaneous picking for several orders.
- By zones: Organization according to warehouse location.
Your choice will depend on the type of warehouse, volume of orders and nature of products. A combination of methods usually gives the best results. (Blog - Solistica)
Measuring success: the numbers that don't lie
As with any critical process, what can't be measured can't be improved. These key indicators will help you continually evaluate and refine your picking:
- Picking accuracy: what percentage of your orders come out perfect the first time? This number should be your obsession.
- Picking time or units per hour (UPH): How long does it take your operators to complete each pick? Speed matters, as long as it doesn't sacrifice accuracy.
- Cost per preparation: At the end of the day, how much does it cost you to prepare each order? This indicator helps you evaluate the return on your improvement investments.
These KPIs will allow you to identify bottlenecks, detect inefficiencies and make decisions based on data, not intuition. (Blog - Solistica)
Logistics transformation in action: a real-life success story
With over twenty years of transforming logistics, our end-to-end systems redefine order picking through intuitive interfaces that provide real-time visibility and precise inventory control. Intelligent merchandise allocation and constant monitoring optimize space and anticipate problems.
After implementing these solutions, our accuracy increased from 92% to 99.6%, reducing error returns by 75%. The return on investment exceeded all our expectations.
Seventy-five percent. The return on investment was much, much faster than we expected." (Blog- Mecalux)
Transform your picking, revolutionize your business!
Contact us today! Our specialists will design a customized strategy that will eliminate errors, reduce costs and make your customers smile with every order.
