SC Codeworks

 Batch/Wave Picking

In the age of Amazon size orders how can a 3PL warehouse process 25,000+ orders in a day? 

One way is to automate the entire warehouse operation that looks like an Amazon Fulfillment operation. Realistically a 3PL cannot afford to put that much capital expenditure and know they will see a solid ROI. 

One of our customers pick over 16,000 per day during normal times and come black Friday/Cyber Monday they can expect to see over 25,000-30,000 orders in one and and yes - they still need to be shipped same day.

Faced with these types of volumes we teamed up and built a solid Batch/Wave picking process in WDLS (Our WMS). As orders are received they are queued up and when the operations team is ready we sort through the orders using a waterfall approach on how best to sort them.

For example we first sort off all the single line orders with the same SKU so those can get bulk picked. Then we will sort through based upon the carrier, the mode of transport, the first warehouse picking zone, as well as a host of other criteria. 

Although WDLS supports a full range of RF and even voice interfaces they found that the best practice is to pick using the packing list (Yes on paper) and let a process we call "Order Validation" catch any mis-picks that may have occurred.

They have all the pickers pick into a tote and then place the tote on a conveyor that brings they to a verification station. Since WDLS has the order verification process built in, they simply scan the packing list and then all the product using a supermarket type of scale and scanning system. If there are any errors in the picking process they are captured here before heading to the packing and then shipping station.

By having all the work processes supported within the same WMS from the production of the packing list all the way to the shipping station order accuracy is maintained at over 99% as well as the labor allocation is well balanced and there are no bottlenecks in the process.

You do not need to invest in a large amount of hardware and automation to address large volumes on B2C orders. What you need is a well thought out layout, an integrated WMS, and an operations team that knock out the orders.

John Khan

V.P. Of Product Development

jkohan@sccodeworks.com

www.ctcodeworks.com