Pick Module

Pick Module

A pick module system is a dense product storage system designed to support the order fulfillment process by moving products efficiently through a warehouse or distribution center. The primary function of a pick module is to automate order picking and order movement through each stage of the order fulfillment process. Pick modules are also called Goods-to-Person or G2P solutions.

Product flow through the pick module system is synchronized and managed by a warehouse control system, such as Numina’s RDS™ Real-time Warehouse Execution and Control System.

Pick module configurations can vary greatly. Typical pick modules combine material handling equipment such as shelving, pallet racks, and mezzanines to create highly concentrated picking zones. They can be single-level or multi-level structures and can be configured to handle a range of picking methods, including split case, mixed pallet case, and full-case picking.

Configurations may also include automated storage and retrieval (AS/RS) systems, automated conveyors, or autonomous mobile robots to bring picked items to the worker rather than the worker walking through the warehouse to pick items. As a result, efficiency increases as operator walk time is minimized and manual picking tasks are eliminated.

Additional automation solutions, such as voice picking systems, pick-to-light systems, and robotic picking applications, can be added to enhance efficiency and increase throughput.

Benefits of Pick Module Solutions

  • Maximize warehouse space utilization by taking advantage of vertical space
  • Reduce warehouse labor costs by reducing employee walktime
  • Increased picking productivity by eliminating walking and manual tasks
  • More efficient inventory management by consolidation of SKUs
  • High flexible implementation by combining a range of warehouse technologies

Increase Efficiency by Combining Pick Modules with Zone Routing Conveyor Systems

Zone routing conveyor systems are a common component of pick module solutions in warehousing to enhance order-picking efficiency. Areas of the warehouse are divided into functional zones, and within each zone, a conveyor system is installed to transport items between different locations or zone picking stations. The conveyor system is designed to facilitate the smooth flow of products within the designated zone.

The automation provided by the conveyor system reduces manual labor and travel time, improves accuracy, and enables better utilization of labor resources. This setup also enables the warehouse to handle a higher volume of orders and enhance overall operational productivity.

Blog: Leverage Pick Modules to Accommodate Higher Order Volumes

Benefits of Today’s Autonomous Mobile Robot or AMR-Based Pick Modules

Advancements in the latest generation of robotic-based goods-to-person (G2P or GTP) solutions have lowered the cost and made the technology suitable for all sizes of warehouse order fulfillment operations.

Today’s G2P robotic automation solutions are also less costly than traditional systems. Early versions of tote and case-based shuttle systems and mini-load storage and picking systems were more expensive as precision steel, international shipping, and installation costs have continued to rise. These costs increase capital investments and extend the return on investment (ROI) to five or more years.

In contrast, the latest G2P warehouse robotic solutions overcome these limitations and are more cost-effective. The newest generation hybrid G2P systems with mobile warehouse robots travel at higher speeds, handle more weight, and reach higher, denser storage shelves than the robotic G2P systems from just a few years ago.

How to Select the Right Pick Module Solution for Your Operations

Today, hundreds of warehouse robotic technologies and options are available to consider. It takes a knowledgeable partner and a design-first approach to analyze key factors, such as the mix of SKU sizes and velocity movement, to determine which pick module solution best suits a specific warehouse operation.

If your product profile is a good fit for a G2P system, for example, the next step is to compare the pros and cons of the various G2P technologies to determine which is best for your specific products, picking, and storage needs.

For best results, work with an independent warehouse automation integrator who evaluates technologies and recommends the right blend of technologies to provide a solution with the most significant efficiencies.

The Numina Group, an industry-leading independent systems integrator, has designed and implemented over 1,000 warehouse automation projects in diverse warehouse environments across North America. We offer one of the industry’s most experienced engineering teams with deep experience in testing, evaluating, and installing various software and material handling technologies.

Learn More

Video: Factors to Consider When Evaluating AMRs and G2P Technologies
Blog: Six Key Features of a Top-Tier WES-WCS
Video Case Study: Medical Supply Company Reduces Order Fulfillment Costs by 60%

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