October 20, 2025
Efficient order picking is a critical component of a successful and profitable warehouse order fulfillment operation. To meet customer demands, manufacturers and distributors need to improve end-to-end warehouse order fulfillment processes. That includes investing in software and automation that work together as a lean, efficient system to reduce labor costs and increase throughput.
There are several technologies that can boost picking productivity. One of the most effective and proven dense product storage and picking solutions, used for each (unit) and case picking, is Pick Modules (PM).
When PMs are designed and slotted intelligently with the right mix of A, B, C SKU movers, warehouses upgrading from a more manual cart or fork-truck-based picking can increase picking speed, maximize storage space, and reduce labor costs.
Pick Modules (PMs) are engineered storage and picking structures that can range from a single-level floor height to multi-level systems with two, three, or four levels. Many PMs include integrated conveyor systems to automate the order/item picking movement between picking zones.
When SKUs are correctly slotted based on order profiles and affinity data, unit pick density increases, reducing operator walk time and improving pick rates by 25% or more.
PMs that include software for optimized order release, and barcode-based automation deliver even faster pick rates and higher order-per-hour output. This is especially true in mixed SKU, unit-based pick-to operations.
Benefits of Pick Modules:
Pick Modules managed by a Warehouse Execution System (WES) software platform, such as Numina Group’s Real-time Distribution Software (RDS)™, leverage advanced Voice-Picking technology for faster, more accurate fulfillment.
The WES software coordinates order selection, release, and cartonization while unifying conveyor-based zone routing with voice-directed operator movement and picking guidance. This delivers major results. The operators are unified with the order picking process throughout the PM to significant improvement over traditional paper-based or mobile RF scanner and terminal-based technologies typically managed by an ERP or WMS system.
1. Hands-Free-Higher Operator Efficiency: Voice prompts guide workers through each step of the order picking process, allowing them to use both hands while confirming picks with a hands-free barcode scanner.
2. Dynamic Realtime Labor Allocation: During order picking, the WES uses voice commands to direct workers to the PM zones with the highest demand in real-time, ensuring optimal labor utilization and maintaining high units-per-hour performance.
Selecting the right picking automation — whether PMs, AMR batch carts, or Goods-to-Person (GTP) systems — should start with data analysis. Reviewing one to two years of order history helps identify the best blend of technologies to maximize throughput and ROI.
Data-driven SKU slotting provides a great roadmap for automation investment. By analyzing product movement (A, B, C), and order profiles you can see the pros and cons of each technology investment and make the choices that maximize your warehouse operation.
For example, slotting analysis in a PM provides the conveyor and order flow path for placing:
1. A Movers: The fastest-moving products (A+) are placed closest to the conveyor zone transfers and may be double-slotted to balance workload.
2. B-C Movers: Slower-moving items (C) are candidates for storing in shelving at the tail end of each pick zone.
3. Continuous Improvement: SKU slotting is an ongoing process. An advanced Voice Picking Suite can capture daily pick data to regularly re-evaluate slotting based on velocity changes especially during peak seasons.
4. Intelligent Slotting Recommendations: Software can suggest location adjustments when product movement no longer matches its assigned A, B, C slot, ensuring:
At The Numina Group, we partner with companies to design first, then identify and find the best blend of warehouse automation technologies that deliver measurable ROI. Our proven data-driven design approach creates a roadmap to streamline receiving, picking, packing, and shipping operations.
Our flagship Real-time Distribution Software (RDS™) is a modular and scalable Warehouse Execution and Control System (WES-WCS) platform that integrates with any WMS and ERP system. RDS provides a complete family of automation modules to optimize your operation, including:
1. Order Release Optimization and Cartonization: Dynamically determines the most efficient carton routing and balances picking across zones.
2. Voice Picking Suite: Industry-leading RDS voice-directed picking technology ensures accuracy and efficiency.
3. Batchbot AMR+ Voice: Automates each and mixed case pallet picking.
4. Goods to Person, GTP: Automated product storage and picking systems.
5. Conveyor and Sorting: Warehouse conveying automation solutions.
6. Pakt™ Automation: Automated pack-and-ship technology, including in-line weighing, vision inspection, sealing, and labeling.
With over 35 years in warehouse automation and software integration, Numina Group understands that every business is unique. We use a team of in-house automation experts to create, evaluate, and provide design and digital twin simulation services to pressure test the final warehouse automation design before implementation.
We work closely with your team to define lean and efficient processes and select the right technologies, whether Autonomous Mobile Robots (AMRs), Goods to Person (GTP), or voice-directed solutions, to deliver the highest end-to-end efficiency and throughput rates.
Ready to explore how Numina Group’s approach to warehouse automation can transform your business? Let’s start a conversation about your challenges and goals. Together, we’ll identify the automation investments that reduce labor costs, increase accuracy, and lower the total cost of fulfillment.
About Numina Group
Numina Group’s RDS™ is a modular and scalable software suite for warehouse automation software solutions optimized to streamline the entire pick, pack, and ship order fulfillment operation.
