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How to optimise order preparation

4min read 22/08/2018

The time taken to prepare orders in the warehouse is a key element in calculating the overall cost of logistics, so all companies try to optimise it.

This is why you must choose the preparation method according to the characteristics of your business.

To improve the order preparation process, the 3 main steps must be optimised :

  • Picking: the operator is responsible for collecting the items that will make up the order
  • Thesorting: once the items have been picked, they must be distributed in the respective orders
  • Packing: once the items have been sorted, they must be packed for shipment.

There are different methods for preparing orders and the effectiveness of the process depends on your needs and your business.

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What is picking?

“Picking is an English term meaning loading, picking. Within a warehouse you can pick up a package from a larger unit such as a pallet or simply from a shelf.

When the warehouse receives large quantities of goods, it is necessary to store the products correctly, to pick only those that are needed each day and to take them to the ‘picking zone‘.

This zone allows you to group the products:

  • Present in small quantities
  • Most popular, the “bestsellers
  • Easily handled or used by order pickers

Once collected in this zone, they are transported to the next packing area.

Picking, like the rest of your warehouse, can be optimised using different methods.

The “Pick and pack” system

How does the Pick and Pack method work?

  • The operator responsible for preparing the order picks up the required products, takes them to the packing area and then returns to collect the products of another order. This method is obviously not the fastest and is suitable for very low daily shipment thresholds.
  • How to improve the ‘pick and pack’ method: the operator picks up items intended for different orders at the same time and distributes them in containers

The ‘put-to-light’ system

How does the Put to light method work?

Put to light literally means “to put in light”, this system uses a trolley equipped with light displays that show the operator where to look for and deposit the necessary products. By flashing, these displays direct the operator to the correct container in an instant. All operations are updated in real time.

The result? Efficient picking in most situations.

Main advantages:

  • Allows the operator to prepare several orders at the same time
  • Allows the operator to minimise the risk of errors

The ‘Pick by light’ system

How does the Pick by Light method work?

This system also uses light signals and is useful when the number of orders is very high.
Lights and light messages are shown on the displays to allow theoperator to easily recognise the pickposition of each item and the number to be selected.
Once the products have been removed, the operator activates the validation of his order, which is received directly from the central inventory management system.

This enables continuous replenishment from the storage area to the picking area to avoid interruptions in the process.

The operator then scans each item in order to depositit in the location indicated by the display light.

The orders are then retrieved and deposited in the packing area.

Thanks to the light signals, the operator recognises the status of the orders at a glance:

  • Green = complete
  • Red = incomplete

This method has many advantages:

  • Enables many orders to be prepared at the same time
  • Increases productivity ofthe entire picking chain
  • Reduces the risk of preparation errors through effective light signalling
  • Reduces order handling time

Put-to-light and pick-by-light systems, however, require computerisation of the warehouse and generate costs.

Despite this, you will recoup your investment quickly due to the increased productivity: the number of picking errors is significantly reduced, operators can prepare several orders at the same time and the management system is optimised to avoid any interruptions from the warehouse.

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