Charge Five Seconds, Save Five Seconds: Optimize Low-Level Order Picking

The low-level order picking process is still noticeably inefficient despite warehouse technology advances, such as pick-to-voice systems. It can take as many as nine discrete actions from when an operator places one case on a pallet to when the next case is placed on the pallet. It remains one of the most repetitive and resource-intensive processes in the warehouse and, consequently, a major opportunity for process improvement.

Steps in the Typical Low-Level Order Picking Process

1. Pick up case
2. Place on pallet
3. Walk to the front of the truck
4. Step on truck
5. Drive truck
6. Step off truck
7. Walk to case
8. Pick up case
9. Place on pallet

Four of the nine actions in the order-picking process are associated with moving the forklift down the aisle to the next pick location. This continual repositioning of the forklift is time-consuming, increases the physical demands on operators and can create safety issues.

The process would be more efficient if the truck could move without the operator having to climb on and off repeatedly. This would compress the nine actions into just five while minimizing the distance operators have to travel and reducing the job’s physical demands. Technology provides the key to streamlining this process through operator-assist features that support more efficient operation.

One proven way to accomplish this goal is to give the operator remote control of the forklift position with wearable technology. Crown’s QuickPick® Rapid equips operators with a wireless device that advances a modified forklift without the operator ever touching the vehicle. This allows operators to work from behind the forklift, moving back and forth across the aisle in an efficient Z-shaped pattern. They no longer have to interrupt their picking to climb on and off forklifts and can position trucks in the exact place they want them, with sensors helping enhance product and rack safety.

Fewer steps can add up to a savings of up to five seconds per pick slot. How valuable are five seconds per pick? While pick rates vary, this can mean a productivity increase of up to 25 percent. In addition, Crown’s easy-to-use wearable device – the Fast-Charge Ring wireless remote – simplifies wearables management. It features five-second pairing at shift start-up and requires only five seconds to recharge using the On-Truck Charger. That means no downtime for swapping and re-pairing of remotes due to discharged batteries. One Fast-Charge Ring provides remote operation throughout an entire shift. These efficiencies simplify the picking process, save valuable time and lessen operator fatigue.

This technology, like voice-enabled picking, delivers the greatest benefits when combined with other process optimizations. Establishing one-way traffic flows, maintaining open aisles, and adopting Z-shaped picking patterns are among other optimizations that should be considered in collaboration with an experienced material handling partner.

As order picking has evolved toward piece picking and order volumes continue to increase, order pickers are under pressure to deliver more productivity than ever before. Operator-assist technologies – such as forklifts controlled by wearable technology – can provide an added productivity boost while enhancing safety and the overall operator experience, five seconds at a time.