What is Zone Picking And What Are The Advantages?
How you pick and prepare items in your warehouse for fulfilment can serious impact on your entire process. This is why figuring out the right picking method that best fits your business is important. One such picking method is zone picking.
Zone picking is a warehouse picking method where the warehouse is divided into different zones, and each picker is responsible for picking items within their designated zone. This system optimizes the picking process, reducing the time workers spend traveling across the warehouse and improving order accuracy.
In this post, we will explore it in detail, highlighting how it works, the pros and cons, and best practices.
Understanding Zone Picking
Also known as pick and pass, Zone picking is a method where the warehouse is divided into several distinct zones, and each zone is assigned to a specific picker or team of pickers. Instead of pickers traveling across the entire warehouse to fulfill an order, they focus solely on their designated zone. This approach minimizes travel time, enhances order accuracy, and significantly speeds up the picking process.
How Does Zone Picking Work?
Zone picking involves several key steps:
Zone Allocation: The warehouse is divided into zones based on product type, volume, or order frequency.
Order Assignment: Orders are split and assigned to the relevant zones by a Warehouse Management System (WMS).
Picking Process: Pickers collect items from their specific zones. For orders that span multiple zones, items are consolidated before shipping.
Consolidation: Items picked from various zones are brought together, checked for accuracy, and prepared for shipment.
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Zone Picking Example
Let’s say you have a warehouse split into 4 zones: 1, 2, 3, and 4, with each zone containing a specific product. In zone 1, you have footwear. Zone 2, jackets. Plaid dresses in 3 and sweatpants in 4.
Then a customer places an order for 20 units of footwear, 30 jackets, 15 plaid dresses and 40 sweatpants. Immediately, you delegate the 4 pickers in your warehouse to retrieve the times from their respective assigned zones.
This is zone picking at play.
Zone picking can be done either simultaneously or in sequence.
Simultaneous Zone Picking
In the simultaneous zone picking strategy, items are retrieved at the same time from different zones by the pickers. The picked items are then assembled in the packing station for final sorting and packing.
Sequential Zone Picking
The sequential zone picking system involves picking items from one zone and then passing the picking bin to the next zone until the last zone. So a picker picks from zone 1 and passes the picking bin to 2 until it gets to 4.
Although might be a bit slower, sequential zone picking can be more effective.
Benefits of Zone Picking
1. Increased Efficiency
Focused Efforts: Pickers concentrate on smaller areas, allowing them to become more familiar with their zone and pick items more quickly.
Faster Order Fulfillment: By reducing the travel distance within the warehouse, orders can be fulfilled faster, boosting overall productivity.
2. Reduced Travel Time
Minimized Movement: Pickers only move within their designated zones, reducing the time and energy spent walking across the entire warehouse.
Less Fatigue: Shorter travel distances mean pickers experience less physical strain, leading to higher productivity and lower turnover rates.
3. Improved Accuracy
Specialization: Pickers develop expertise in their zones, leading to fewer mistakes and higher accuracy in order fulfillment.
Consistent Quality: With a focused area, pickers can maintain a consistent quality of work, reducing the chances of errors.
4. Scalability
Easy to Scale: As the business grows, new zones can be added and new pickers can be assigned without disrupting the existing workflow.
Flexible Management: Zone picking can adapt to changes in order volume, product range, and warehouse layout.
Disadvantages of Zone Picking
1. Complex Coordination
Multi-Zone Orders: Orders that span multiple zones require additional steps to consolidate picked items, which can complicate the process and introduce potential delays.
Dependency on Coordination: Effective communication and coordination are essential to ensure that multi-zone orders are consolidated accurately and efficiently.
2. Imbalanced Workloads
Varying Demand: Some zones may have higher picking demands than others, leading to imbalanced workloads and potential inefficiencies.
Need for Dynamic Management: Regular assessment and reallocation of zones may be required to balance the workload, which can be resource-intensive.
3. Initial Setup and Training
Time-Consuming Setup: Dividing the warehouse into zones and setting up the necessary systems can be time-consuming and complex.
Training Requirements: Pickers need thorough training to become familiar with their zones and the overall zone picking process, which requires time and resources.
Other Picking Methods
The zone picking method might not always be ideal for your business. Other picking methods to consider include:
Wave Picking: This involves picking products in waves at specific time intervals.
Discrete Picking: Discreet picking is a warehouse management method where each order is picked individually and sequentially. It’s best used in small storage facilities.
Batch Picking: In this picking method, similar orders are grouped into batches and then picked simultaneously.
Best Practices for Zone Picking: Maximizing Efficiency in Your Warehouse
1. Design Efficient Zones
Creating well-designed zones is the foundation of effective zone picking. Here’s how to optimize your zones:
Group Similar Items: Place similar items together within a zone to minimize the time pickers spend searching for items.
Consider Order Frequency: Allocate high-demand items to zones that are closer to the packing and shipping areas.
Balance Workload: Ensure that each zone has a balanced workload by regularly reviewing order data and adjusting zones as needed.
2. Utilize Technology
Leveraging technology can significantly enhance the efficiency of your zone picking process:
Warehouse Management System (WMS): Implement a robust WMS to manage orders, track inventory, and optimize picking routes.
Real-Time Data: Use real-time data to monitor and adjust zone picking operations continuously.
Automation and Robotics: Integrate automated systems and robotics to assist with item movement within and between zones, reducing manual labor.
3. Train Your Workforce
A well-trained workforce is crucial for the success of zone picking:
Comprehensive Training: Provide thorough training for pickers on how to use the WMS, understand their specific zones, and follow the picking process.
Continuous Learning: Encourage continuous learning and skill development to keep pickers updated on new technologies and processes.
Effective Communication: Foster clear communication channels between pickers and supervisors to quickly address any issues or bottlenecks.
4. Implement Efficient Picking Strategies
Optimizing your picking strategies can further enhance the benefits of zone picking:
Batch Picking: Group multiple orders together and pick them in batches to save time and reduce travel distance.
Pick and Pass: Use a pick and pass system where pickers pass the partially completed order to the next zone, ensuring a smooth flow of items through the warehouse.
Wave Picking: Schedule picking waves to align with shipping schedules, ensuring orders are picked and packed just in time for dispatch.
5. Monitor and Analyze Performance
Regular monitoring and analysis are key to continuous improvement in zone picking:
Track Key Metrics: Monitor metrics such as picking speed, accuracy, order fulfillment times, and picker productivity to identify areas for improvement.
Feedback Loops: Implement feedback loops to gather input from pickers and supervisors, and use this feedback to refine processes.
Regular Audits: Conduct regular audits of zones and picking processes to ensure compliance with best practices and identify any potential issues.
Conclusion
Zone picking is a powerful method for improving warehouse efficiency and accuracy. By strategically dividing the warehouse and optimizing the picking process, businesses can achieve faster order fulfillment and better scalability. As technology continues to evolve, the future of zone picking looks promising, with advancements in automation and AI set to further enhance its benefits.
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