Order preparation

Given this situation and the growing complexity of the market, today more than ever it is essential to evaluate the effectiveness of this process, to ensure that optimal levels of productivity are maintained and any type of lag against the competition is avoided.

One way to verify that your DC order preparation is being effective is by analyzing the following:

Is the arrangement of the SKUs correct?

To streamline the assortment processes, it is always important to verify that SKUs with greater movement or rotation are located in more accessible positions than those with low rotation.

Likewise, it is essential to verify that the products are classified by:

In this way, in the event that the arrangement of the SKUs does not meet these criteria, it is advisable to carry out a rearrangement and classification, so that operators can optimize their picking times.

*G.I.Eicom Tip:
We recommend dividing this process into several stages, in which approximately 10% of the SKUs are rearranged each month. This will facilitate the process and minimize the time spent on it.

Is the Gold Zone being used?

The Gold Zone is rated as the ideal zone to place SKUs in the storage area, as it reduces the risk of injury and significantly increases the productivity of the assortment by preventing operators from bending over or grabbing products overhead.

Is there a picking strategy in place?

In order to have defined and orderly processes, and to achieve a level of logistical excellence in the assortment of orders, it is important that your Distribution Center has a well-established picking strategy. The most prominent are:

	Batch picking: It consists of registering, selecting, and filling more than one order at the same time.
	Zone picking: When the warehouse is divided into multiple zones and operators are assigned to fulfill the order fulfillment in a single determined zone.
	Pick and pass: When orders are transferred from one zone to another until their complete consolidation to be ready for shipment.
	Consolidación: It is normally used in conjunction with a “zone picking” strategy. Here, each zone simultaneously collects the SKUs required for an order and they are sent to a specific consolidation zone, and then proceed to their respective shipment.

Why automate?

Given the accelerated technological evolution and the multiple challenges generated by the COVID-19 pandemic, today more than ever the immense need to automate the processes related to order preparation has been detonated, in order to maintain a high degree of competitiveness and successfully meet the demands of consumers.

However, despite the great benefits that order assortment automation brings, we find that some companies often hesitate to invest in this type of technology, due to certain myths that frequently revolve around this issue.

The most common are usually:

"All my DC’s have to be automated"

Although it is true that, in general, at a higher level of automation, you can obtain a Distribution Center with greater vanguard and productivity, the reality is that each DC is different and, therefore, has particular needs.

Therefore, it may not be necessary for all of your Distribution Centers to be fully automated. You can start semi-automating your assortment processes with various picking technologies, which can range from amazingly simple to very sophisticated depending on convenience, and still achieve significant productivity improvements.

"Automation takes a lot of time."

On many occasions, automation projects may seem very time-consuming due to the number of factors that must be considered, such as: the creation of the design concept, the selection of the technology that best suits the needs and operations of the DC, the development of simulations and planning of the start-up, etc.

However, when you have the technical advice of a provider specialized in this type of solution, the automation project can be developed and implemented in incredibly attractive periods of time.

Of course, each project has its own peculiarities that make it simpler or more complex, but it is the level of expertise of your supplier that will make this process an agile and successful process.

"Automation reduces the number of employees."

This premise is not necessarily true. The automation of processes does not always imply the dismissal of employees or generate additional costs for their training.

It is important to remember that, depending on the objectives to be achieved, the type of technologies to be implemented and the business strategy, the results will be obtained.

What is a fact is that the rate of human error in operations is minimized, achieving a high level of safety and productivity thanks to the ergonomics of the facilities and the simplification of processes that automation technologies provide?

"Automation generates a loss in control of the DC"

If the automated system is designed and implemented correctly, far from causing a loss of control in the processes, automation will help you eliminate many problems that are normally generated when management is carried out manually. In addition, it becomes an excellent ally as the volume of operations increases.

"Automation is always expensive"

Finally, although it is true that the initial investment may seem a bit high, when you compare it with the benefits obtained, the reality is that the return on investment (ROI) of your automation project can have remarkably interesting rates.

However, for this, a lot also has to do with the experience of your provider. Hence the importance of looking for a specialist in the intralogistics solutions sector, who has a long-proven track record and a robust local support system.

Pick to Light & Put to Wall

The Pick to Light and Put to Wall technology works based on a system of illuminated displays that indicate to the operator the exact quantity of products that must be supplied from each SKU to complete the preparation of an order.

When the orders are finished, the only thing that the operator has to do is confirm by means of a button, to be able to continue with the next one.

Profits

	Real time system
	Automatic inventory updates (indicating what needs to be refilled)
	Interconnectivity whith other automatisms
	99.9% picking accurancy
	Easy adaptability to slotting changes
	Pick to Light Productivity: Up to 1,100 lines person/hour
	Put to Wall Productivity: Up to 600 lines person/hour

Put to Light

Similar to Pick to Light, Put to Light is an order fulfillment system designed to visually guide personnel. In this, the luminous displays indicate to the operator the position to which he must go to complete each order.

With Put to Light, operators must confirm orders in all positions that required product, in order to continue with the next zone until the order consolidation is completed.

Profits

	Real time system
	Automatic inventory updates
	Interconectivity with other automatisms
	99.9% picking accurancy
	Easy adaptability to slotting changes

Pick Cart

The Pick Cart is a technology that works by means of a cart that contains several illuminated displays to indicate the quantity of pieces to be taken from each shelf in a specific position.

Here, the displays show where the products should be placed for each order, as well as the quantity to be supplied in the cart; so that the operator repeats this process until the orders are completed in the different areas.

Profits

	Simultaneous assortment of several orders
	Flexibility of adaptation to other technologies
	Maximum picking precision (99.9%)
	Productivity: Up to 300 lines person / hour

Autonomous Mobile Robots (AMRs)

The mobile robots or AMRs are the result of the innovations of intralogistics 4.0, to automate the processes of assortment of the Distribution Centers. These robots are controlled by software that integrates artificial intelligence mechanisms, which gives them the ability to perform operations autonomously.

Likewise, these technologies operate under the “Good to Person” principle, which is why they are designed to bring the products to be supplied to the consolidation stations, so that the operator can prepare the order.

Thanks to this, AMRs have been especially useful for assortment in e-Commerce channels.

Beneficios

	Easy integration with Pick to Light, Put to Light technologies, among others
	High flexibility to scale the solution
	Maximum safety and ergonomics of operation
	Productivity: Up to 500 lines person / hour

Mobile Robots 3D

Like AMRs, 3D mobile robots also have the ability to mobilize autonomously thanks to the intelligent software that controls them. However, their particularity is that they can move both horizontally and vertically when anchored to the storage racks.

Likewise, 3D mobile robots make it possible to take advantage of storage space in a much more productive way, since they also integrate a high-density vertical storage system. Being Good to Person solutions, they generate a completely agile and safe environment for operators, allowing order preparation in less than 5 minutes!

Profits

	Throughput and / or storage scalability without stopping the operation
	Storage density 5 times higher than traditional shelving systems
	Robots with a maximum load capacity of 30 kg.
	Productivity: Up to 600 lines person / hour

Shuttle XP

The Shuttle XP is an automated warehousing solution, ideal for applications that require medium to high throughput in distribution. They integrate different technologies, such as Pick to Light, barcode readers and software interfaces, to guarantee a maximum level of precision in the assortment.

Beneficios

	Savings of up to 85% of the useful storage area
	Modular design that allows it to adapt to any required height, both before and after installation
	Good to Person Solution
	Productivity: Up to 450 lines person / hour

Vertical Buffer Module LR35

The Vertical Buffer Module LR35 is a highly efficient solution for the storage and assortment of products with light weight and small volume. It has features designed with maximum ergonomics in the picking stations, to simplify the order preparation process.

Its cargo containers support up to 35 kg. And integrate technologies such as barcode scanners and Pick to Light systems to increase the speed and precision of picking.

Beneficios

	Controlled access that guarantees the safety of stored products
	Maximum energy efficiency (consumes a third of the energy of comparable systems)
	Easy scalability thanks to its modular design
	Good To Person Solution
	Productivity: Up to 500 lines person / hour

Vertical carousel

Vertical carousels serve to streamline the order picking process by providing quick and accurate access to stored products. These solutions are especially suitable for items with a high frequency of picking, since they bring the tray with the product that is required through the shortest possible path.

Profits

	Save up to 75% of storage space
	Productivity increases of up to 60%
	Maximum security of the stored merchandise
	Good To Person solution
	Productivity: Up to 450 lines person / hour

Horizontal carousel

Horizontal carousels are ideal solutions for fulfillment operations with high recovery rates and medium to slow product flow. This system is supported by Pick to Light technologies to indicate the quantity of items to be supplied.

In this automated warehousing solution, items are stored compactly in a reduced space, eliminating unproductive picking routes in the warehouse.

Profits

	Allows you to handle all kinds of products
	Ergonomic design
	High flexibility thanks to its adaptive design
	Good To Person solution
	Productivity: Up to 450 lines person / hour

The specialized item sorter is an exceptional technology for consolidating orders at high speeds. It is characterized by having a "loop" shape, as well as by the use of trays to move, classify and supply different types of products.

With this solution, the operator performs the picking process by placing the products on the trays, so that when the system detects ー through a barcode reader ー that a certain item is required to complete an order, it deposits automatically in your consolidation zone.

Beneficios

	Maximum safety when handling products
	Easy integration with Pick to Light technologies
	Ideal for irregularly shaped products
	Productivity: Up to 13,300 items / hour

1) Pick to belt

The Pick to belt is a comprehensive solution for box order picking, encompassing various technologies such as radio frequency (RF) systems, Pick to Voice and different types of conveyors.

The design of this solution consists of the installation of a belt conveyor in the center of a designated area, where operators receive (through Pick to Voice systems) the instruction of which products should be placed on the conveyor for their respective assortment.

Subsequently, through radio frequency technologies, the system detects where each product should go to complement each order. Once the order is consolidated, a sorter sends it to your boarding area.

Profits

	Reduction of working hours
	Productivity increases of up to 200%
	Ergonomics
	Decrease in operating expenses

Shoe sorter

The Shoe sorter is a widely used solution in multiple industries thanks to the fact that it allows classifications and assortment of products at high speeds.

This sorter is one of the most flexible sorting equipment on the market, as it can handle a wide variety of products weighing up to 40 kg. In addition, it allows to implement dual outputs (left and right), as well as versatile geometric arrangements.

Profits

	Aluminum design for optimal product glide
	Convenient maintenance
	Silent
	Throughput: Up to 400 products per minute
	Handling of various types of products

Cross belt

The Cross belt is a high-end sorter for classifying and sorting products at high speeds. Unlike other sortation systems, the Cross belt allows you to handle products of various dimensions, weights, and depths without them suffering any kind of damage.

Likewise, it is a very versatile system that can be installed in a linear or “loop” shaped with bidirectional or unidirectional output arrangements.

Profits

	Maximum safety when handling products
	Ideal for products with different characteristics and / or amorphous typology
	Cost savings for space and operation
	Throughput: Up to 500 products per minute

Narrow belt

The Narrow belt is distinguished by being a product sorting and assortment solution for medium flows..

This sorter can be configured with unidirectional and bidirectional arrangements according to the operational requirements of your DC, in addition to offering a higher output density per linear foot by providing the possibility of diverting the product at 30 ° or 90 °.

Profits

	Maximum ergonomics
	Silent
	Sorter with the best energy savings on the market
	Simple and inexpensive maintenance
	Throughput:Up to 120 boxes per minute

Push-up Wheel

The Pop-up Wheel is a sorter used in order fulfillment applications that handle medium to high flows. The peculiarity of this equipment is that the units to be handled must have a flat and rigid base, so its use is ideal for cardboard boxes or plastic totes.

Its design is made up of a single band that intersperses different deviations to carry out order consolidation. It is a team with great flexibility to integrate various outputs according to the needs of your Distribution Center.

Profits

	Increase in assortment productivity
	Minimal maintenance required
	Versatility of outputs
	Throughput: Up to 80 boxes per minute

1) Unit-load AS/RS

The Unit-load AS / RS is a specialized equipment for the storage and assortment of pallets. It offers fast, smooth, and reliable performance thanks to its state-of-the-art design.

It can measure up to 40 m. high, easily adapting to the load and weight profile of your products, as well as to the construction dimensions and operating environment of your DC.

Profits

	High speed operation
	Adaptative design
	Safe operation for employees
	Forklift traffic reductions
	Simple maintenance

2) AGVs (Automated Guided Vehicles)

AGVs are one of the main technologies that have replaced the use of forklifts for pallet assortment operations thanks to their great flexibility, in addition to considerable increases in productivity.

This solution is very versatile since it allows you to design and modify the trajectories of the vehicles according to the requirements of your operation. Over time, AGVs have evolved to a great extent, so in addition to being more reliable, they have become much more accessible.

Profits

	Greater safety for operators
	Possibility of operating 24/7
	Versatility of applications and configurations
	Safety in handling products

Preparation of e-commerce orders

Before the emergence of the COVID-19 pandemic, e-commerce order preparation was distinguished from other distribution channels by its high level of demand in delivery times and the marked peaks in demand derived from different seasons of offers and promotions.

After COVID-19, we can see how these badges gained even more strength thanks to the exponential growth that electronic commerce has had during this time (+ 300% in Latin America according to Kantar).

However, all kinds of challenges have also been added to the above, such as:

How to optimize e-commerce order preparation?

To carry out a project to optimize the assortment of orders for an e-commerce channel, it is first necessary to carry out an analysis of the specific needs of the company, taking into account its economic capacity together with other analytics related to its operation, the profile consumer, among others.

Once this analysis is completed, it is possible to define the type of technological infrastructure that will be required to be implemented within the Distribution Center; always bearing in mind that gradual automation can be incorporated to avoid strong undercapitalization.

Learn more in these blog articles:

1) WMS

Whether your Distribution Center is conventional, semi-automated or fully automated, the WMS (Warehouse Management System) is the elementary software to manage all the tasks that must be carried out daily within the DC.

Some of its most outstanding features consist of managing:

	Recipits of goods
	Organization and monitoring of activities carried out by staff
	Traceability of stocks
	Storage of products logically and precisely
	Order preparation process
	Shipment of goods
	Analysis of results and creation of reports

2) WCS

The WCS (Warehouse Control System) is the software that allows to control all the operations sent by the WMS regarding the activity flows. This tool is in charge of “giving instructions” to the automatisms about the tasks that they must carry out, analyzing the fluidity and effectiveness of each one of them.

In addition, WCS helps to collect valuable data from the operation, to transmit it to the central management software, analyze it and provide a more accurate view of the performance of the DC.

Principal functions:

	Direct and maintain control of automation
	Task synchronization
	Real-time data collection
	Sending notifications in real time about possible problems related to the execution of activities

It should be noted that, from the level of semi-automation, the implementation of the WCS becomes essential.

3) WES

The WES (Warehouse Execute System) facilitates the execution of tasks in environments with multiple automation and great complexity between processes. It is designed to interconnect each process, giving an immediate response to all automation equipment according to the necessary requirements.

With the passage of time, this software has evolved to the extent that, currently, it is no longer a simple execution program, but now allows combining WMS and WCS functionalities.

Most important functions:

	Process improvement
	Material flow management
	Execution and control of supplies
	Enrichment of the intelligent dynamics of the DC

Analysis of alternatives

Each automation solution involves a series of alternatives that must be carefully analyzed, to define the one that presents both greater viability and greater tangible and intangible advantages for your DC.

Projection of the solution

Likewise, it is essential to forecast the life cycle or the capacity that the solution will have in the future, considering the growth projections of the Distribution Center.

Financial analysis

Another important factor to consider is the financing method with which the investment will be made. Whichever mechanism you choose, don't forget to factor in capital inflation!

Finally, what would the automation project be if it did not have the advice of a supplier specialized in the development of this type of solution?

Make sure you have the support of a company highly experienced in intralogistics automation, whose reputation is proven in the market, and which in turn guarantees a robust local support that allows you to operate under the most demanding standards 365 days a year.

At G.I.Eicom, we want to be that ally that helps you guarantee an order preparation system capable of successfully responding to current and future market demands.

	Profitability
	Maximizing the use of space
	Precise inventory control in real time
	Continuity of the operation
	Safety when handling products

	Working conditions for operators (fewer accidents)
	Delivery times and precision
	Continuous improvement of the customer experience
	Among others

	Inventory control in real time
	Increses in picking speed up to 10-15
	Comfortable and ergonomic assortment by allowing the operator to have his hands free
	99.9% picking accuracy
	Productivity: Up to 200 lines person / hour

How to evaluate its effectiveness?

Is the arrangement of the SKUs correct?

Is the Gold Zone being used?

Are the picking and storage technologies designed for the SKU typology?

Is there a picking strategy in place?

Are the assortment processes constantly evaluated?

Learn more about the effectiveness of order picking here!

Why automate?

"All my DC’s have to be automated"

"Automation takes a lot of time."

"Automation reduces the number of employees."

"Automation generates a loss in control of the DC"

"Automation is always expensive"

And what are the benefits of automating order picking?

Keep learning about automation in these blog articles:

Automation technologies

Tecnologies for item assortment

1) Picking technologies

2) Robot technologies

3) Automatic stogare

4) Sorter specialized fot items

Tecnologies for assortment of boxes

2) Sorter systems

3) Mini-load AS/RS

Technologies for assortment of pallets

Preparation of e-commerce orders

How to optimize e-commerce order preparation?

Learn more in these blog articles:

Specialized technologies for the assortment of e-commerce orders

Softwares for precise control in real time

We recomend you:

How to ensure maximum ROI when automating?

Analysis of alternatives

Projection of the solution

Financial analysis

	Maximum safety when handling products
	Simple and inexpensive maintenance
	Throughput: Up to 45 boxes per minute

	Controlled access for maximum storage security
	Quiet performance
	Easy scalability
	Simple maintenance