Zone Picking
Zone picking is an order fulfillment method in which products are organized into designated areas, or “zones,” in the warehouse, and workers are assigned to pick orders from specific zones. Zone picking is often deployed in large warehouses or distribution centers (DCs) with high-volume order processing and tight processing times.
Zone Picking Benefits
Zone-based picking reduces the time and distance workers travel to complete pick tasks, resulting in higher efficiency. Zone picking can also improve order accuracy, as workers are trained to pick from specific zones and are less likely to pick the wrong item or quantity of items.
Blog: Combine Voice Picking and Zone Routing Conveyor Picking to Increase Productivity
To implement zone picking, products are typically grouped into specific areas of the warehouse based on factors such as their size, weight, and frequency of use, and workers are then assigned to pick within those areas. Orders are then routed to the appropriate zones for fulfillment, and workers pick the items and add them to the order.
Zone Picking Technology Enhancements
Zone picking can be used with other automation technologies, such as conveyor belts and automated storage and retrieval systems, to streamline and optimize the order fulfillment process.
For example, zone-picking efficiency can be increased by implementing a zone routing conveyor. This brings the work to the operators who typically work in 1 to 2 pick zones on a level with a pick module.
Voice-picking technology can also be added to increase order accuracy and picking throughput. Voice-directed picking, when combined with zone routing pick-to-conveyor modules, will outperform manual batch order cart or pick-pass conveyor systems. Pick-by-voice systems provide the highest level of picking efficiency and accuracy.
Greater efficiency is achieved when voice-picking technology is coupled with a wearable touch-screen display for hands-free barcode scan validation to keep the operators’ eyes focused on performing the work.
Warehouse Execution Software to Synchronize Order Picking Tasks
Numina Group’s Real-time Distribution Software (RDS™), our flagship Warehouse Execution and Control Software (WES-WCS), contains a complete family of automation modules for order release optimization, cartonization, pick-by-voice and pick-to-light and other warehouse order fulfillment technologies.
The RDS WES-WCS system can:
- Pre-determine or dynamically determine carton zone routing for the most efficient route
- Balance picking across pick zones when high-mover SKUs are slotted in multiple zone locations and
- Control the conveyor to ensure that tote and cartons travel only to the assigned pick zones
Additionally, RDS can synchronize and manage picking from zones outside the pick modules for full-case order picking or slow-moving SKUs better suited for storage outside the pick module.
Zone Picking Considerations
If you’re interested in learning about optimizing your order fulfillment operations with process improvements and warehouse automation, the Numina Group can help. As a leading warehouse automation design consultant, software developer, and independent systems integrator, Numina Group has over 40 years of experience defining, designing, and implementing highly profitable automated warehouse systems.
Our automated warehouse solutions enable companies to:
- Increase productivity by 50% or more
- Reduce labor costs by 30% to 70% and
- Increase order accuracy to 99.9%
We offer consultative warehouse design services to identify the right lean processes for your operations. We help you turn your design into reality by combining the power of RDS™ WCS-WES, our real-time warehouse control and execution software, with cutting-edge material handling technologies.
Learn More
Video Case Study: Frozen Food Company Reduces Labor Costs by 50%
Video: NorthShore Care Supply Doubles Productivity with Batch Picking Combining Voice Picking and AMRs
Blog: How Pick Modules and Zone Route Conveyors Keep Warehouse Pickers on Task
