What really matters when it comes to picking solutions:
Optimizing picking processes with assistance systems

Manual? Fully automatic? And also safe? In many places, order picking is carried out in fundamentally different ways. However, companies should consider the systems available at an early stage to improve their processes in the long term. Given the large selection of picking solutions, it is advisable to see the manufacturers on the market not only as producers, but also as individual consultants. They provide an overview of suitable systems for the respective application.

There are many methods for picking in the warehouse: from manual picking by employees to devices that carry out the work fully automatically. What is ideal for one customer is not necessarily ideal for another: solutions must meet individual requirements. Regardless of the industrial sector, whether aircraft and mechanical engineering or wood and plastics: valuable goods must arrive at the next production stage or at the end customer without being damaged. For many companies, this poses major challenges. This is not least due to the removal of heavy and bulky goods such as panels from a rack and their transportation for loading. Typical industries that deal with heavy materials are familiar with the dangers and consequences such as scratches, breakages and damage to the goods. Last but not least, employees are also severely challenged by such processes. In order to protect the goods and employees, there is a whole range of systems that provide a remedy and help to optimize picking processes.

Decisive factors in the selection process

A decisive factor in the selection of the optimum picking system is the turnover rate in the warehouse. In some warehouses, goods are only stored for a short time before they are transported onwards. In other warehouses, on the other hand, the turnover rate may be lower because, for example, a buffer warehouse contains different products in different designs and sizes that need to be moved irregularly. "Throughput is one of the decisive factors," explains Pascal Schütz, Managing Director of DIMOS, one of the German manufacturers of custom-built industrial trucks, sideloaders and order picking vehicles for long, heavy and bulky goods. "It is therefore clear that there is no one-size-fits-all solution. It is not necessarily the case that an automated solution is worthwhile for every customer. In some cases, the manual option may also be right."

In the selection process, the weight and dimensions of the parts to be moved must be considered in addition to the handling frequency. This also determines how many aisles there are and how wide they are. The size of the shelves and the storage space available for order picking are also crucial. Another decisive factor is whether customers are looking for a solution for a new build or for an existing warehouse. In any case, the new systems must fit in with the overall processes and do justice to the operational procedures. It is also important to check whether individual production processes are already automated. High productivity and efficiency in warehouse operations are only possible with coordinated processes.

In order to make the right choice for a system, the required number of employees must also be taken into account. The degree of automation depends on this: the more automated the process, the lower the number of employees required. "However, automation is not about replacing people, but rather about relieving the physical strain on employees. The shortage of skilled workers can also be countered under certain circumstances. Automated processes can also form the basis for an additional unmanned shift. Valuable employees can then be deployed elsewhere," explains Pascal Schütz.

Many options: manual, semi-automatic or fully automatic solutions

The basic design of some models of electric multidirectional sideloaders is already suitable for handling long goods. If there is mixed traffic in a warehouse, i.e. the ratio between order picking and putaway work is similar, there are suitable semi-automatic intermediate solutions consisting of electric multidirectional sideloaders and order picking platforms. Supplemented by the pick-up platform, the electric multidirectional sideloader is the ideal solution for medium or constantly growing storage capacities. "The great advantage of this modular solution is its flexibility," says Pascal Schütz. "Companies use the electric multidirectional sideloader for medium handling capacities for load handling and order picking."

For companies with a high tonnage turnover that want to relieve employees, the modular extension with special vacuum suction devices is also suitable. In this way, no hard physical work is required and the goods are also protected from damage: Extendable suction cups suck up individual panels from the shelf compartment and then place them safely. In this case, only one person is required for operation and monitoring.

This solution of electric multidirectional sideloader and order picking platform is not sufficient for high or rapidly increasing handling rates. This is because one disadvantage of the interaction is the one-sided order picking. The opposite compartment can only be picked by turning the vehicle. One solution recommended by manufacturers of special vehicles is the electric picking platform, which enables picking on both sides (even in narrow aisles). Picking is optimized through the integration of operating stations, telescopic forks or scales. This automated picking platform, which is equipped with assistance systems, is networked with the warehouse management system and all other relevant processes via interfaces. This makes processes safer and more efficient - thanks to functions such as automatic shelf positioning. Orders are shown to the operator directly on the display. The correct storage location in the warehouse is also stored here. The platform then navigates the shelf to the compartment that matches the dimensions. "Thanks to automation, storage space can be used efficiently, there is less paperwork and orders are processed automatically, taking into account short travel distances. This halves travel times and optimizes order picking," explains Pascal Schütz.

Companies achieve an increase in speed and precision with fully automated storage and retrieval machines. However, before these are implemented, it is important to check whether this solution will benefit the business at all. This is because storage and retrieval machines often do not have the desired flexibility, which is particularly required during peaks, despite higher travel speeds and consequently a higher turnover of goods.

Conclusion

"As customer-specific as the requirements are, the picking solutions have to be just as individual," says Pascal Schütz. "In order to find the optimum solution for a specific application, you have to get an idea of the conditions on site as well as the customer's requirements." Standard systems often do not meet these requirements and the individual requirements of warehouse operators are increasing. As a specialist, it is therefore essential to offer individual advice and support users in their selection. Through careful analysis of the warehouse, they find auxiliary systems that optimize the picking processes through their integration into the overall processes.