Split case picking, also known as broken case picking, is a labor-intensive operation in today’s distribution centers. As e-commerce continues to increase and currently represents around 15.4% of all retail sales in the US, there is a greater need for effective and cost-efficient split case-picking systems that cater to the unique demands of businesses and operations.
What is Split Case Picking?
In split-case picking, the process involves selecting individual items from separate locations and putting them into a container, usually a shipping carton or tote. Unlike methods where entire pallets or full cases are picked, this approach demands more handling of products and generates more cartons, which naturally translates into increased labor requirements.
Who Will Do the Picking?
There are three main options: people, machines, or robots. Most operations mainly rely on humans for picking. It’s important to note that robot-based picking is advancing quickly.
How will the Picking Be Done?
You should decide whether you want to organize the picking process based on the entire order or individual items. If you choose to pick by order, you won’t need to sort items further downstream. However, if you opt for picking by item, downstream sorting will be necessary to organize the items into their respective orders. Here are the primary methods of order picking:
Discrete Order Picking
Discrete order picking is especially common in e-commerce and retail settings, where individual customer orders vary widely in terms of the items they contain. This method ensures accuracy in fulfilling each order, but it may not be as time-efficient as batch picking for high-volume, identical items.
Cluster Order Picking
Cluster order picking is particularly effective in environments where orders share common items, allowing for efficient use of labor and reduced travel within the warehouse. While it might not be as accurate as discrete picking for orders with diverse items, it significantly improves picking productivity for large numbers of similar orders.
Batch Picking
Batch picking streamlines order fulfillment by grouping similar orders into batches based on specific criteria like product type, location, or delivery routes. Workers receive a consolidated picking list that encompasses multiple orders within a single batch, allowing them to collect all required items in one efficient pass through the warehouse. Items are verified during picking, sorted to avoid mix-ups, and then packaged for individual orders. Batch picking excels in reducing travel time, making it particularly effective for processing numerous small orders or those sharing common items, enhancing productivity and efficiency in high-volume order fulfillment.
Wave Picking
A method that optimizes order fulfillment by organizing the process into distinct “waves” or groups, usually based on criteria such as delivery time, product type, or customer priority. Workers are assigned specific waves, focusing on picking items for orders within their designated wave, which minimizes travel time. After picking and verifying the items, they are sorted, packed, and prepared for shipment. This approach is particularly efficient when handling a large number of orders, enhancing overall warehouse productivity by systematically streamlining the fulfillment process.
Maximizing the Process
Now that we’ve covered the various picking methods you can define how to maximize your order-picking operation by carefully selecting and combining various picking methods to align with your specific needs. Here’s how:
Evaluate Order Characteristics: Understand the nature of your orders. Are they predominantly small, similar, or diverse in their item profiles? For small and similar orders, batch picking is efficient. For diverse orders, consider discrete order picking.
Analyze Order Volume: Assess the volume of daily orders. For high volumes, wave picking can help organize and streamline the process. For moderate volumes, discrete or batch picking can be effective.
Assess Warehouse Layout: Consider your warehouse layout and product organization. If the warehouse is well-organized with easily accessible items, discrete or batch picking may suffice. If it’s more complex, wave-picking might be beneficial.
Labor Resources: Analyze your available labor resources. If you have a skilled workforce, discrete picking can maintain high accuracy. For cost-efficiency with less skilled labor, wave or batch picking can help.
Technology Integration: Determine the level of technology integration in your operation. If you have advanced picking technology, like barcode scanning or automated systems, it can enhance accuracy and speed, complementing all picking methods.
Customer Expectations: Consider customer expectations, including delivery time and accuracy. Wave picking can prioritize orders based on delivery times, while discrete or batch picking can ensure high accuracy.
Flexibility and Adaptability: Ensure the chosen method allows for flexibility and adaptability to handle changing order profiles and seasonal fluctuations.
Continuous Improvement: Implement a system for continuous improvement, regularly reviewing and optimizing your picking methods to adapt to evolving business needs.
By carefully assessing these factors and aligning them with the most suitable picking methods, your company can tailor its order-picking operation to maximize efficiency, accuracy, and overall performance, ultimately meeting customer expectations and business goals.
