Warehouses are often very large. It can be a long process for pickers to find a certain SKU in the warehouse, complete the picking, and then return to the workstation.
This practical problem has promoted the widespread application of automation in the logistics industry, especially in the warehouse picking process.
If you’re considering introducing automation into your warehouse picking process, you’ve come to the right place.
This article will give you a comprehensive introduction to automated warehouse picking systems, including system types, core advantages, and the leading automated picking solutions provided by Modula APAC.
What is an automated warehouse picking system?
Automated warehouse picking systems (also known as automated order picking systems) are a type of solution that optimizes the picking process through technical means, which can significantly improve picking accuracy and operation speed.
Such systems usually integrate equipment, picking robots, and advanced software systems for inventory management and guiding warehouse operators to complete picking tasks in real time.
Types of automated warehouse order picking systems
The automated picking system improves warehouse operation efficiency through a variety of technical means.
It can be mainly divided into the following three categories:
- Assisted Picking Systems:Assisted picking systems optimize the manual picking process by introducing picking assistance technologies such as Pick-to-Light and voice picking systems.
The light picking system prompts the picking location through indicator lights, while the voice picking system issues voice instructions to the operator through a headset. These technologies improve picking accuracy and reduce the time employees spend searching for materials. - Goods-to-Person (GTP):Goods-to-person automation systems use robots and conveyor equipment to deliver materials directly to warehouse operators.
This method of order fulfillment significantly reduces walking and search time, further speeding up picking. - Automated Picking Systems:The fully automatic picking system is a solution that does not require manual intervention and uses robots to automatically complete the storage and withdrawal of materials.
This type of system is extremely efficient and is especially suitable for warehousing environments with large order volumes and fast turnover.
How does automated warehouse picking work?
The automated warehouse picking process usually includes the following steps:
- Choose the right picking system:Devices such as automated guided vehicles (AGVs) or autonomous mobile robots (AMRs) are capable of autonomously navigating warehouses with little or no human intervention.
Using sensors, cameras and advanced software systems, they can avoid obstacles and choose optimal driving paths. - Integrate with existing warehouse management systems (WMS): The automated order picking system will be integrated with the warehouse management system (WMS), and the WMS will assign tasks and guide the automated system to pick up the goods at the designated location.
- To perform a picking operation:Different automated picking systems are suitable for different warehouse needs. For example, a robotic arm equipped with a suction cup or gripper can grab materials from a shelf; in a voice picking system, employees wearing headphones complete the corresponding picking tasks according to voice instructions.
- Sorting and placement:The robot transports the picked materials to the sorting area and sorts them according to shipping needs.
- Quality control and verification:Scanning devices and sensors verify that the picked SKU matches the customer order and confirm that the material is in good condition, reducing mispicking.
Which companies are suitable for automated warehouse picking?
Automated warehouse picking systems can improve efficiency and accuracy in multiple industries that rely on accurate inventory management and rapid order fulfillment.
Especially suitable for the following types of businesses:
- E-commerce industry:High order volumes and fast delivery requirements make automated warehouse picking the key to ensuring efficiency and customer satisfaction.
- pharmaceutical industry:Automated picking systems ensure accuracy and traceability of the picking process, which is critical when handling sensitive pharmaceuticals and meeting strict regulatory requirements.
- Food and Beverage Industry:Automated picking systems help implement the “first in, first out” (FIFO) principle, which is particularly important for the management and freshness of perishable goods.
- Auto parts suppliers:Automated picking systems can improve picking speed and accuracy in multi-category inventory and reduce delivery errors.
- Electronics and high-tech industries:Automated picking systems can handle high-value, fragile materials accurately and safely, reducing the risk of damage during handling and storage.
- Third-party logistics (3PL) service provider: 3PLs often need to manage inventory and order fulfillment simultaneously for multiple customers, and automated picking can help increase throughput and reduce operating costs.
- Manufacturing factory: Automated picking optimizes supply chain processes and speeds up production by getting parts to the production line on time.
Core Benefits of Automated Warehouse Picking
Automated warehouse picking systems offer many advantages, including:
- Improve picking efficiency and speed:The automated system can operate at high speed and continuously, greatly improving order picking efficiency, thereby achieving faster order processing and delivery.
- Improve picking accuracy:Automated picking systems reduce human error and ensure the right materials are picked accurately every time, thereby reducing returns and error correction costs.
- Improve employee safety:Automation reduces the need for manual handling of heavy objects or retrieval from heights, reduces the risk of workplace injuries and creates a safer working environment for warehouse employees.
- Support scalability and flexibility:Automated picking solutions can scale with order volume and have the flexibility to handle different sizes and types of products, allowing them to quickly respond to demand changes and inventory fluctuations.
Challenges of implementing an automated warehouse picking system
When introducing automated warehouse order picking systems, companies also need to address the following challenges:
- Personnel training:Employees need to be trained to operate automated picking systems safely and efficiently, which requires an investment of time and resources.
- Maintenance and repair costs:Automated systems require regular maintenance and unscheduled repairs to ensure continued operation, which can be complex and costly. For example, a single picking robot typically costs around A$11,000.
- Difficulty of integration with existing equipment:Integrating automation systems into existing warehouse infrastructure is not easy, and often requires technical adjustments to the process, such as re-planning job layouts and upgrading software systems to achieve smooth collaboration.
Discover Modula APAC’s reliable automated warehouse picking systems
At Modula APAC, we can speed up your picking process with customized automated warehouse picking systems.
We provide advanced robotics technology, proven software integration solutions, and comprehensive training support to ensure your team can use these systems effectively.
Here are some of the available Modula automated picking solutions:
- Modula Lift:Modula Lift frees up to 90% of warehouse floor space, increases operational efficiency by 2–3 times, and improves picking accuracy to nearly 100%.
Its external pickup port (External Bay) can be integrated with a crane or mechanical assist device to facilitate the handling of heavy materials. - Modula Put to Light System:The Put to Light system can replace traditional paper picking lists and shipping lists, supports batch or multiple order modes, realizes simultaneous picking of multiple orders, and greatly improves overall throughput capacity.
- Modula Picking Station:Modula picking workstations are designed for batch or multi-order processing. They can operate individually or in combination with multiple workstations, providing flexible and precise picking solutions to help you complete more orders in less time.
Review of key points for automated warehouse picking
Overall, automated warehouse picking can help warehouse operators reduce picking errors and significantly improve production efficiency.
Automated warehouse picking systems include but are not limited to:
- Robotic arm
- Vertical Lift Module (VLM)
- Goods-to-Person (G2P) technology
- Light picking system (Pick-to-Light)
- Automatic guided vehicle (AGV)
- Autonomous Mobile Robot (AMR)
At Modula APAC, we provide diversified picking solutions to help companies achieve more efficient and precise warehouse operations by improving material positioning efficiency, speeding up picking, and optimizing work processes.
Warehouses can be massive, and it can be quite a trek for pickers to locate a SKU, pick the item, and then return to their station.
This challenge has spurred the adoption of automation in the logistics industry, especially automated warehouse picking.
If you’re looking to introduce automation into your warehouse picking processes, you’re in the right place.
We’ll cover everything you need to know about automated warehouse picking systems, including types, their benefits, and introduce the leading automated picking systems at Modula APAC.
What Are Automated Warehouse Picking Systems?
Automated warehouse picking systems, or automated order picking systems, are technological innovations that optimise the picking process, enhancing picking accuracy and speed.
These systems include machinery, picking robots, and advanced software to manage inventory and direct warehouse operators in real-time.
Types of Automated Warehouse Order Picking Systems
Automated picking systems enhance warehouse operations through various technologies.
The three primary types include:
- Assisted Picking Systems: Assisted picking systems streamline manual processes by incorporating technologies like pick-to-light and voice picking systems. Pick-to-light systems utilise lights to signal which items to pick, while voice picking systems deliver spoken instructions through headsets. These innovations enhance picking accuracy and decrease the time workers spend searching for items.
- Goods-to-Person (GTP) Picking Systems: Goods-to-person automated systems use robots and conveyors to deliver items directly to the warehouse employee. This type of order fulfilment innovation minimises walking and searching, further accelerating the picking process.
- Automated Picking Systems: Automated picking systems are fully automated solutions that leverage robots to retrieve items without human intervention. These fully automated solutions are highly efficient and particularly beneficial in high-volume, fast-moving environments.
How Does Automated Warehouse Picking Work?
Here’s how automated warehouse picking typically operates:
- Choosing the right picking system to use: Robots, such as automated guided vehicles (AGVs) or autonomous mobile robots (AMRs), can navigate the warehouse with minimal or no human intervention. Sensors, cameras, and advanced software enable them to avoid obstacles and select efficient routes.
- Integrating with the existing warehouse management system (WMS): Automated order picking systems integrate with a warehouse management system (WMS) that assigns tasks and directs automated systems to the required items and locations.
- Picking: Various automated order picking systems meet specific warehouse needs. For instance, robotic arms equipped with suction cups or grippers pick items from shelves. On the other hand, in voice-directed picking, employees wearing headsets follow voice commands that direct them to pick the correct items.
- Sorting and placement: Robots transport picked items to a sorting area where they are categorised for shipping.
- Quality control and verification: Scanners and sensors verify that picked SKUs match the customer’s order and are in good condition, reducing mispicks.
Which Businesses Can Benefit From Automated Warehouse Picking?
Automated warehouse picking improves efficiency and accuracy across various industries that rely on precise inventory management and quick order fulfilment.
Here are the businesses that benefit most from automated warehouse picking systems:
- ECommerce: High order volumes and the need for rapid turnaround make automated warehouse picking paramount for maintaining efficiency and customer satisfaction.
- Pharmaceutical Operations: Automated order picking systems ensure precision and traceability, which is crucial for handling sensitive medications and complying with strict regulations.
- Food and Beverage Industry: Automated order picking systems uphold the first-in, first-out (FIF) principle. This is essential for managing perishables and preserving freshness.
- Automotive Parts Suppliers: Automated order picking systems boost retrieval speed and accuracy across a wide range of inventory, decreasing distribution errors.
- Electronics and High-Tech Industries: Automated order picking systems can manage delicate and high-value items with accuracy and care, reducing the risk of damage during handling and storage.
- Third-Party Logistics (3PL) Providers: 3PLs manage inventory and fulfilment for multiple clients, using automated picking to increase throughput and reduce operational costs.
Manufacturing Facilities: Automated picking optimises supply chains by delivering components just-in-time to production lines, speeding up production.
Key Benefits of Automated Warehouse Picking
Automated warehouse picking offers a host of benefits, and can:
- Boost productivity and speed of picking: Automated systems operate at high speeds and can function continuously, accelerating the rate of order picking. This efficiency leads to faster order processing and deliveries.
- Amplify order picking accuracy: Automated order picking systems diminish human errors and costly returns by consistently securing the right item every time.
- Streamline worker safety: Automation reduces the need for manual tasks such as lifting heavy items or reaching extreme heights, decreasing the risk of workplace injuries and creating a safer environment for warehouse staff.
- Support scalability and flexibility: Automated picking solutions scale to accommodate increased order volumes and are flexible enough to handle diverse product sizes and types. Additionally, automated order picking systems quickly adapt to changing demands, so your business can effectively manage fluctuating inventory levels.
Challenges of Implementing Automated Warehouse Order Picking Systems
Implementing automated warehouse order picking systems comes with its own set of challenges that businesses need to navigate:
- Training: Employees require training in effectively and safely operating automated picking systems. This demands time and resources to ensure they’re up to speed with the new technology.
- Maintenance and repair: Automated systems need regular maintenance and occasional repairs to remain functional, which can be complex and costly. For example, robot pickers typically cost AUD 11,000.
- Integration with current equipment: Integrating new automated systems into existing warehouse infrastructure can be challenging. It often requires technical adjustments and significant changes to current processes, such as reconfiguring workflow layouts and updating software systems for seamless operation.
Discover Reliable Automated Warehouse Order Picking Systems at Modula APAC
At Modula APAC, we can accelerate your picking process by implementing bespoke automated warehouse picking systems.
We provide advanced robotics, sophisticated software integration, and comprehensive training to ensure your team can efficiently manage our advanced systems.
Here are some of our automated picking systems your business can utilise:
- Modula Lift: The Modula Lift can recover up to 90% of warehouse floor space, boost efficiency by two to three times, and improve picking accuracy to nearly 100%. The Modula Lift features an external bay that integrates with picking aids such as cranes or mechanical manipulators, facilitating the handling of heavy materials.
- Modula Put to Light System: Our Put to Light System replaces traditional paper-based methods like picking tickets and shipping lists. It operates in batch or multi-order modes, significantly increasing your throughput by enabling the simultaneous picking of multiple orders.
- Modula Picking Station: Our Picking Station is designed to efficiently handle batch or multiple order processes, ensuring a seamless workflow. It can operate independently or in multiple configurations at set positions. It provides a versatile and accurate solution, allowing you to complete more orders in less time.
A Quick Recap on Automated Warehouse Picking
To recap, automated warehouse picking can help your warehouse operators reduce picking errors and heighten productivity levels.
Automated warehouse picking systems include:
- Robotic arms
- Vertical lift modules (VLMs)
- Goods-to-person (G2P) technology
- Pick-to-light systems
- Automated guided vehicles (AGVs)
- Autonomous mobile robots (AMRs)
At Modula APAC, we offer a range of picking solutions that simplify the process by improving item location, accelerating picking speeds, and streamlining operations for greater efficiency and precision.
