duplicate data entry are examples of
major time-wasters.
What to do about it? Ask the team for
ideas and, for a different perspective,
consult with specialists in warehouse
technology. A new layout might help,
or maybe it’s time for investment in a
modern WES.
3. Suboptimal Picking
If picking isn’t done efficiently, ob-
viously time and money are wasted.
Yet what does “efficient” look like?
Ideally, picking minimizes time and
movement, with the goal of maximiz-
ing units picked per hour. Warehouse
automation can help with this by
implementing automated retrieval
and picking solution.
Not taking full advantage of data
reading and entry technologies can
also lead to suboptimal picking.
Mistakes are made, potentially cre-
ating double handling and inventory
issues. The solutions are to standard-
ize processes, including pick routes,
and invest in appropriate automation
for data handling/inventory manage-
ment.
4. Poor Layout/Space
Utilization
Achieving good space utilization has
taken on new urgency with the rise of
e-commerce. In fulfillment centers,
there’s more movement and picking,
increasing the cost of poor layout.
Also, warehouse locations close to
population centers often occupy
more expensive land, which drives up
costs.
Using WES data to identify the most
frequently picked items and then,
rearranging storage locations to min-
imize distance traveled for picking
these. Additionally, explore what new
racking and storage technology could
do to positively effect utilization. For
example, a high-density automated
8. Avoiding Product Damage
storage/ retrieval system (AS/RS)
could significantly increase space
utilization.
There are myriad of reasons that
product can be damaged in a
warehouse. Sometimes this is found
during picking.
5. Product Diversification
Aligned with the growth of fulfill-
ment centers, warehouses are holding
a wider variety of items than ever be-
fore. While WES capacity isn’t usually
one of the top warehouse problems,
the increase in picking work most
definitely is. As with space utilization,
the answer lies in using a WES to
determine optimal storage algorithms
to increase picking efficiency. Also,
look at ways of reducing the physi-
cal work involved in fulfilling these
picking tasks. It’s possible that an AS/
RS is the ideal answer.
6. Seasonal Demands
How do you allocate space as work-
load varies seasonally? Configuring
the warehouse for peak demand
means potentially leaving areas un-
derutilized the rest of the year.
Warehouse automation products offer
solutions. Pallet flow systems, new
racking, and more capable lift and
boom trucks can also boost units per
hour handled, as can a complete
AS/RS. Increasing capacity this way
provides “headroom” for the busy pe-
riods without saddling the operation
with poor space utilization the rest of
the year.
7. High Labor Costs
Managers at distribution and ful-
fillment centers are under increased
pressure to reduce costs while im-
proving service levels.
Picking is still, for now, a highly man-
ual task, although solutions continue
to emerge. Consider how technology
can increase pick rates and how pallet
flow systems and AS/RS technology
should be part of the solution.
www.WestfaliaUSA.com
Modern racking and pallet flow
systems can move product more care-
fully than older technology. Cases are
decelerated and zero pressure systems
maintain a minimum separation to
prevent damages. AS/RS is, once
again, another solution.
9. Handling Returned Items
File this under “poor layout” if you
want, but it’s a problem big enough
to warrant a separate heading. As
e-commerce has grown, so too have
return volumes. A common problem
with an informal or haphazardly
planned system incurs double
handling. What’s more, poor record
keeping results in workers spending
time resolving queries.
As a potential solution, start by
understanding the product flow and
documenting the activities being
conducted in the warehouse. From
there, move into standardization and
assess how technology could help.
Automation providers experienced
in assessing warehouse problems
and providing efficient solutions may
have ideas you haven’t considered.
Industry-Appropriate
Solutions
We realize that there’s no one-size-
fits-all answer to every warehouse
problem. Asthe facts are gathered will
they begin the process of developing
the appropriate solutions, whatever
form they may take — AS/RS, WES,
or conveyor and pallet flow systems.
The Satellite Review
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