May 09, 2020

Warehouse system processes (Part 2)

Warehouse system processes (Part 2)

Order picking 

The process of order picking in a warehouse involves selecting and gathering the specified amount of right SKUs in accordance with the order and it is composed of lifting, moving, picking, putting, packing, and other related activities. During the order picking process, the orders are generally assigned to many pickers. However, in order to prevent control problems, the total pick area is often divided into picking zones. After this, the zones are generally served by different pickers, through the zoning policy. Orders are picked one by one or in batches in a predetermined order. Further, order picking can be manual or automated. In manual order picking, the picker gathers units from their locations then transports them to a parking area. Picking time Tp is calculated as shown below

=t1+t2+t3+t4 (1)
t1 –average travelling time [s];
t2 –average extracting and searching time [s]:
t2=x1·x2· ti (x1– average number of locations per
order [pieces], x2– average number of positions
per location [pieces], ti – time needed for picking
on one position (3-6) [s]);
t3 –information processing time [s]: t3= (10–15 s)·x1;
t4 –time for additional activities [s] (t4=75 – 300
s for hand pallet truck, t4= 70 – 250 s for lowlevel order picker, t4= 55 – 200 s for high-reach
In the case of automated picking, that is, automated storage and retrieval systems, system retrieves one or more unit loads and place them to a picking station. After that, the picker takes products on orders, and therefore the remaining items on the unit loads are transferred to storage again.


The process of packing can be demanding because every previously picked unit is generally handled separately. At this time, the process of checking the picked order is also required and convenient and there is less chance for errors to occur. Order accuracy may be a crucial measure of service to a customer. If inaccurate orders make it to the customer, there will appear new expenses such as returns, which are expensive to handle.
This process must be dealt with caution and awareness. The basic task of packing is to organize goods for further transportation by any carrier during a way that doesn't affect shipping costs during a negative manner. If there's a complication with picking orders, there'll be complication with packing. Precisely, if all items from the order are not positioned at the same time at a packing area, it is likely that the shipment will be delayed or/and costs will increase. The shipment can be sent partially resulting in higher costs


The process of shipping is the final process amongst warehouse processes. After packing and preparing units for shipping (consolidation), the first step is loading into transportation vehicles with the assumption that the shipping methods have been previously arranged. This process is not as complex and generally includes less labour than mentioned before, although there can be some additional activities if the product is being staged before being loaded. Also, the outbound zone can include control, which will often occupy at least one warehouse worker to provide the activity. Depending on the warehouse information system, control can be done manually or using a scanner

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