Picking process: main problems

In logistics, the picking process is responsible for picking up packaged units or sets from a higher packaging unit that contains more units than those extracted. We can speak of unit picking when unitary products are extracted from a box or box picking when boxes are collected from a container called packing.

<<< Main problems in product distribution logistics >>>

The picking process is a very important operation in the preparation of orders in warehouses, which greatly affects the productivity of the entire logistics chain since in many cases it represents the great bottleneck of it. Likewise, it deals with customer service and represents more than 60% of the total cost of a warehouse.

Through the picking process, the products are separated, checked, packed, and shipped. Any error throughout this process can cause not only a delay in delivery but also the shipment of the wrong products, which will lead to a possible loss of customer confidence in the company.

To prevent your company from incurring this type of failure in the picking process, in this article we identify the main problems that frequently appear and that have an easy solution. It is just a matter of attending to the needs of each stage of the process.

1. The correct units are not found where they should be.

This frequent error implies that a product unit isn't in its storage location, which forces the people in charge of this activity to waste time looking for the missing item to relocate it to its place of origin. But in addition, they will have to find out the cause of its loss.

This error causes a delay in the fulfillment of the order and also subsequent ones, making this process inefficient, eternal, and unproductive. To solve this problem, hire a warehouse logistics management software that allows you to control and record all the units stored in the warehouse and to be able to detect when any unit is not in its place.

The management tool ensures the correct execution of the process by updating the position of the product in the stock. In case the stockist places one of the products in a different place than the one suggested by the software, the software will automatically send a notification.

2. Errors in the classification of the units.

Errors at the time of separation or classification of the units can generate various consequences. The first consequence is that a failure of this nature is noticed at the time of shipment and requires requesting the collection of the order again. This will cause a waste of time and manpower.

The second consequence is that, if the fault is not noticed, the wrong product will be sent and this will bring with it considerable financial losses and, not least, customer dissatisfaction for not receiving the order in the corresponding time.

To calculate the cost of these errors, you can use as a market measure the application of a simple calculation: multiply the number of occurrences per week by the cost of each one. In this way, the cost of losses can be identified based on this wasted time.

The best way to prevent this problem from manifesting itself is to record all the movements of the picking process in the warehouse. A management tool will also help you monitor each of the stages of the process so that you do not lose sight of any of the products and avoid the wrong products from being separated.

3. Picking process carried out manually.

One of the most tedious tasks in the world is to carry out the picking process manually, that is, writing down on paper lists to be able to locate the units in stock. Imagine the unnecessary time your collaborators waste doing this repetitive manual data entry and the high probability of human error that they generate.

The most practical solution is to eliminate paper from the picking process and automate the process through a digital tool to carry out this separation of orders. Thanks to the technology, the operator will be able to be guided by the application and avoid the collection of units from being poor or wrong.

In addition, the same system will notify the end of the process at the exact moment, which will prevent new delays from being generated.

4. There is no priority order.

When orders are not prioritized according to your business model, you risk delaying orders that deserve your attention to be shipped as soon as possible. This will jeopardize the bond between the company and the customers.

To solve this problem, you must use a method to classify orders by setting parameters in the warehouse management system, where you take into account the schedules of the carrier, the urgency of the orders, and the delivery route.

From there, the system defines which orders should be separated together or individually and, finally, includes indicators to control the process path.

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5. Many workers in the warehouse. 

Excessive labor in the warehouse can result in several headaches. For example, having an inadequate layout; if the plant design is not adequate or the spaces have been used poorly, there will be a greater effort to separate the merchandise. Without a strategic distribution of the warehouse, you will have more maintenance expenses and personnel to separate the orders.

On the other hand, not having a warehouse management tool that manages the processes and tasks of the warehouse, the work of the operators loses effectiveness and efficiency, for which all the decisions fall on supervisors and this can bring about errors in the layout of the warehouse elements, making the picking process more uneven.

The most effective way to increase the productivity of order picking is by implementing technological solutions to automate processes in the warehouse, as long as a process review has been previously carried out.

Automation will avoid the efforts of manual work, providing greater efficiency and productivity, it will save labor and personnel to attend to the same volume of orders and will provide a global picture of the needs of the warehouse that will allow functional decisions to be made, aimed at optimizing the processes of your business.

6. Lack of organization in the warehouse

A warehouse that has only one picking position can generate all kinds of organizational problems in the warehouse because it forces the staff to place the rest of the orders in empty places. These actions, at the same time, encourage workers to memorize the spaces occupied by their merchandise because someone could change their place and not find out.

A warehouse management tool can help you optimize organization and make better use of your warehouse space by suggesting strategic location spaces, directing all positions according to their turnover rate.

7. Impossibility of tracking the person responsible for the picking process.

When what is done in the operation is unknown, it is not possible to measure the efficiency and progress of the picking process; for this reason, it is necessary to monitor it through the warehouse management system to know everything about order preparation if it is delivered in the established time, if it arrives in good conditions, etc.

A warehouse manager allows you to generate indicators that provide real-time visibility of movements, to correct common deviations that arise during the picking process.

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In conclusion, although it is difficult to control the picking process so it's always efficient, implementing a warehouse management tool allows you to reduce many of the problems listed, which is a huge strategic and competitive advantage to improve product delivery processes.