Improving efficiency is key to the success of any warehousing business. Zone picking is a warehouse picking method that is used to make the order picking process more efficient and to increase productivity. It is most often used in warehouses that stock many different SKUs, and have different types of products. Zone picking can be used as the sole picking method or in combination with other picking strategies.
What is Zone Picking?
Zone picking is a method of order picking in which different zones are created within the warehouse. These zones can be arranged by the types of products, SKUs, how fast a product sells, different picking or storage requirements, etc. The order pickers are then assigned a zone or a station where they carry out the picking procedure. Each picker stays in their zone and picks only the products from that zone.
Zone picking uses product-driven pick lists instead of order-driven pick lists, meaning that employees are assigned to pick certain products that are within their assigned zone instead of moving between the different zones to complete a certain order.
In larger warehouses that fulfill orders with many different SKUs, for one employee to travel across the warehouse to locate several SKUs can result in a lot of wasted time. Therefore, zone picking can really improve efficiency in these types of warehouses. Employees assigned to specific zones gain familiarity with their areas and reduce their picking time and potential errors.
Different Zone Picking Strategies
There are two main zone picking strategies that warehouses use: sequential and simultaneous. The different strategies may require a different layout and even different types of equipment to implement effectively. Deciding on a strategy will help you determine how to set up your warehouse effectively for zone picking.
In sequential zone picking, one cart is used to collect the different products. The first item is put into the cart and then it’s transferred to the next zone and the picker adds the next item from their zone to the cart. The cart is moved down through the zones until the entire order is fulfilled. The cart is then consolidated at the end. In simultaneous zone picking, each product from each zone is placed in a separate cart and at the end of the picking process, the carts are combined into the same order. As the name suggests, each picker can work simultaneously and doesn’t have to wait for the cart to arrive in their zone to begin picking.
What Equipment is Used for Zone Picking?
Implementing zone picking in your warehouse requires creating a layout and plan for how the orders will be processed. When you have the layout figured out, you can then decide on what kind of equipment to use and where to place them for optimal efficiency. Here are the equipment that are used for zone picking:
Barcode Scanners
Zone picking requires multiple employees to work on the same order. Barcode scanners are a great way to keep track of the products and eliminate mistakes. They streamline the process compared to keeping track of everything manually.
Warehouse Management System
A Warehouse Management System (WMS) is essential to a high-volume warehouse that uses zone picking. WMS is a type of software that keeps track of all order data and makes the communication between the different fulfillment stages easier. The data that is collected through barcode scanners is passed on to the WMS and eliminates the need for manual management.
Bins & Totes
Bins and totes are used for holding products during the picking process. Bins help keep different parts of the same order in the same container. These work especially well for smaller parts and items that would easily get lost. Bins and totes are also great for storing products and make it easy for pickers to identify contents.
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Gravity Conveyors
Gravity conveyors use gravity to move products down the line. They are used in zone picking to speed up the transportation of products between different zones and workstations. The surface of the gravity conveyor can be made of different materials such as rollers and skatewheels to accommodate different box or crate shapes. Gravity conveyors can also be set up to transport products between different levels of the warehouse, such as a mezzanine.
Carton Flow
Carton flow is a type of dynamic shelving that uses gravity to move products from the rear end of the shelf to the front. It is commonly used to increase the efficiency of order picking. The product is loaded from the back and as the products in the front are picked, the ones in the back slide forward and replace them. Carton flow reduces the need to reorganize products on the shelf as they are picked and keeps the employees responsible for loading out of the way of those who do the picking. It not only speeds up the picking process by providing easier access to products but also maximizes the storage space in your warehouse.
Warehouse Picking Carts
Picking carts are used to store and transport products during the picking process. Picking carts often have several levels that can be used to store different SKUs or order numbers. They allow the orders to remain separate while picking simultaneously. In sequential zone picking, once all of the products from one zone are added to the cart, it can be passed on to the next zone to resume the fulfillment.
Create An Effective Zone Picking System With the Right Equipment
Whether you’re setting up a new warehouse and designing a zone picking system from scratch or reconfiguring your existing warehouse to improve your current picking operations, American Storage & Logistics has all of the equipment you need to build cost-saving and efficient pick modules. We have a complete inventory of in-stock carton flow, pallet rack, gravity conveyors, and stock picking carts in both new and used condition, ready for same-day pickup or next-day delivery. Click here to shop online today or give us a call at 616-246-9800 to speak with a sales engineer today!
