Order Picking
More than half of the labour cost of a warehouse is spent on picking. This is where the gains and the losses both start.
- Horizontal picking
- Vertical picking
- Multi-order picking
- Voice guidance
- Ergonomics
The most expensive step in the warehouse
Order picking covers everything from taking goods off the rack to having them ready for dispatch. It is the most labour-intensive step of a warehouse operation, which is why most of the total labour cost arises here.
Most of the picking time goes into reaching the item, not into taking it. The shorter the time the operator spends walking the aisle or driving, the more orders the same team gets out per day.
- Horizontal picking: Picking from ground level, where walking distance is the deciding factor.
- Vertical picking: Picking in high racking, with the operator lifted together with the goods.
- Multi-order picking: Picking several orders at the same time on a single round.
Five reasons picking productivity drops
The problems we see on site usually come from a mismatch between process and truck, not from the truck choice itself.
- The operator spends a large part of the shift walking.
- A separate round is made for every order and the same aisle is visited again and again.
- Ladders or unsuitable trucks are used to reach high rack levels.
- The pick list is on paper; error and return rates are high.
- The truck was not chosen for the lift height and aisle width, so the round takes longer.
- The current round data is measured first; walking time and driving time are separated.
- A single-order, multi-order or zone picking model is proposed to suit the order structure.
- A horizontal or a vertical order picker is positioned according to the picking height.
- Trucks are integrated with voice and light guidance and with fleet software.
- The truck family is determined together with the aisle width and the rack height.
Four steps from measurement to commissioning
We put figures on the current situation before proposing a truck; the proposal always rests on measurement.
Site Analysis
Aisle widths, rack heights, order line counts and current round times are measured on site.
Process Design
The picking model, the zone split and the routing logic are built around the order structure.
Truck Selection
A truck family that fits the chosen model is proposed, together with battery and equipment options.
Commissioning
Installation, operator training and on-site follow-up through the first month are handled by the Expartise team.
Truck families used in this step
Picking height and aisle layout are the two main criteria behind the truck choice.
What a well set up picking process delivers
The items below are the ones we measure during the site analysis and measure again after commissioning.
Time per Round
Once route and truck fit together the picking round gets noticeably shorter; the same team gets more orders out.
Error Rate
Guided picking reduces the returns caused by the wrong item or the wrong quantity.
Operator Ergonomics
The right truck reduces bending and reaching, and with it the risk of lost working days.
Use of Space
Narrow aisle trucks allow more pallet positions in the same area.
Frequently asked questions about order picking
Do we have to change our existing racking?
In most cases no. We first assess the truck options that suit the existing aisle width and rack height. Changing the racking only comes up if space gain is the target and the return on the investment can be calculated.
How long does the analysis take?
It varies with the size of the warehouse, but the measurement on site usually takes one day. Once the order data has been shared, the assessment report is ready within a few working days.
Can we try a truck before we buy?
Yes. With short-term rental you can test the truck in your own warehouse with your own orders. We recommend this above all for trucks that change working habits, such as vertical order pickers.
What do you do about safety during picking?
Picking aisles are areas where pedestrian and truck traffic mix. That is why we treat collision avoidance and speed limiting solutions as part of the process design in picking projects.
Let us measure your picking process together
- Site analysis and measurement of the current situation
- A picking model proposed to suit your order structure
- A solution configured from the STILL truck range
- Installation, operator training and after-sales support
As an authorised STILL Arser dealer and service partner we run the whole process in one place: site analysis, installation, operator training and after-sales support.