Logistics picking: automation for “zero error” logistics

Is your warehouse a profit center or a source of hidden costs? The answer often lies in a single activity: picking .

This step, which involves picking items to prepare orders, represents up to 60% of a warehouse's operating costs . It's a manual, repetitive operation, and therefore extremely prone to errors. One picking error, and the entire value chain is impacted : customer returns, dissatisfaction, reshipping costs, loss of confidence, etc.

However, a solution exists and it is redefining the standards of logistics performance: the automation of picking .

Reducing your preparation errors by more than 99%, operators two to three times more productive and without additional effort… This is the reality brought by automation.

By reading this comprehensive guide, you'll understand how automation, orchestrated by WMS software, can transform your order preparation into a decisive competitive advantage.

So, are you ready to build the warehouse of the future?

Picking: The strategic heart of the warehouse

Before diving into the solutions, let's take a look at picking and its challenges. Why is it both so central and so complex for supply chain optimization?

What is picking in logistics?

Picking is the process of collecting items from the warehouse to fulfill customer orders . It is the first concrete step in fulfilling an order.

The basic process seems simple:

1. Receipt of the preparation form (picking list).
2. Moving the operator to the item location.
3. Taking the right amount of product.
4. Depositing the item in a container (parcel, bin, order preparation trolley).
5. Validation of the operation and moving on to the next article.

This apparent simplicity hides an immense operational complexity, especially when the number of references and orders explodes.

The picking equation: 60% of costs, 100% of customer impact

Picking is the most expensive and time-consuming activity in warehouse logistics. Operator movements alone account for more than 50% of the total preparation time . Every step is a cost. Every second wasted searching for a product is a loss of productivity.

The consequences of inefficient picking are direct and measurable:

• Increased operational costs: More time spent per order means more labor required.
• Slowdown in logistics flows: A picking bottleneck paralyzes the entire shipping chain.
• Explosion of errors: A manual and repetitive process increases the risk of product reversals, quantity errors, etc.
• Customer dissatisfaction: Picking errors are the number one cause of disputes and returns, directly damaging your brand image.

Logistics flow management begins with perfect mastery of order preparation. This is where profitability and customer loyalty are won or lost.

Order preparation methods

To optimize picking, you must first understand how it works. There are two main philosophies:

1. Man-to-Goods: This is the traditional method. The picker moves through the warehouse aisles to retrieve the products. It's simple to implement, but it's also the least efficient method in terms of travel time.
2. Goods-to-Man: Here, the logic is reversed. The products are automatically transported to a fixed preparation station where the operator only has to pick the necessary items. This approach, at the heart of automation, drastically reduces travel and boosts productivity.

The choice between these methods depends on your volumes, the number of references, and your investment strategy . But one thing is certain: the future is leaning massively towards "Goods-to-Man".

Comparative analysis of picking automation technologies

Picking automation isn't a single solution, but a range of technologies with distinct strengths and weaknesses. The best choice for your warehouse will depend on your specific context.

Pick-to-Light: Guided by light

Pick to Light is a visual assistance system. Illuminated displays are installed on the shelves at each storage location. When an operator needs to pick an item, the corresponding display lights up, indicating the exact location and quantity to be picked. The operator simply follows the light, picks the product, and presses a button to confirm.

Benefits :

• Drastically reduced errors: Visual guidance is intuitive and reduces the risk of confusion. Accuracy rates exceed 99.5%.
• Increased Productivity: Eliminates the time spent reading a paper order form and searching for the location. Productivity gains can be as high as 40%.
• Quick start: Training of new operators is almost instantaneous.

Disadvantages:

• Installation cost: Equipping each location with a display represents a significant initial investment.
• Lack of flexibility: The system is fixed. Changing the warehouse layout or adding new SKUs can be complex and costly.

Ideal for : Areas with high product turnover (Class A according to ABC classification), where speed and accuracy are paramount.

Voice Picking: Hands-Free Efficiency

With Voice Picking, the operator is equipped with a headset and microphone connected to a portable terminal, which is itself connected to a Warehouse Management System (WMS). The system dictates its instructions verbally : where to go, which product to take, and how much. The operator then confirms each action aloud ("OK," "Done," or by reading a control code).

Benefits :

• Hands and eyes free: The operator can fully concentrate on his picking and driving movements, which improves safety and ergonomics.
• High accuracy: Confirmation dialog and check codes allow for very high levels of accuracy, often exceeding 99.9%.
• Flexibility: Less rigid than Pick-to-Light, it adapts more easily to changes in the warehouse.

Disadvantages:

• Noisy environment: May perform less well in very noisy warehouses.
• Equipment cost: Requires specific terminals and headsets for each operator.

Ideal for: Warehouses with a large number of references, refrigerated or frozen environments (where handling paper or screens is difficult).

Vision Picking (Pick-by-Vision): Augmented reality for precision

This is the most cutting-edge technology. The operator wears connected glasses (augmented reality glasses) that display all the necessary information directly in their field of vision : direction arrows, location of the highlighted product, quantity to be taken, product visual. Validation can be done by voice command or by an integrated scanner.

Benefits :

• Ultra-intuitive guidance: Information is contextual and visual, reducing the cognitive load on the operator.
• Versatility: Can integrate barcode reading, taking photos in case of anomaly, and guiding through complex processes.
• Maximum precision: The combination of visual guidance, code reading and voice confirmation aims for “zero errors”.

Disadvantages:

• Maturity and cost: The technology is still young, and the cost of equipment remains very high.
• Operator Acceptance: Wearing glasses for long periods may require an adaptation period.

Ideal for : Complex picking processes (kitting, assembly) or pioneering companies wishing to invest in Warehouse 4.0 technologies .

Autonomous Mobile Robots (AMR): The agility of “Goods-to-Man”

Here, we move into another dimension: "Goods-to-Man". Instead of the operator moving, autonomous mobile robots (AMR) retrieve the shelves containing the required products and bring them directly to the preparation station . The operator remains static. A light system (similar to Pick-to-Light) indicates on the shelf which product to pick. Once the task is completed, the robot leaves to tidy the shelf and another arrives with the rest of the order.

Benefits :

• Spectacular productivity: Eliminates almost all travel time. Productivity can be increased by 3, 4, or even more.
• Scalability and flexibility: It is easy to add or remove robots depending on peak activity .
• Space optimization: Allows for greater storage density because aisles can be narrower.

Disadvantages:

• Major investment: Represents the largest initial investment, although it is increasingly accessible through rental models (Robots-as-a-Service).
• System Dependency: Requires a robust IT infrastructure and WMS to manage the fleet.

Ideal for: E-commerce with very high order volumes and a large number of references, distribution centers that need to ship very quickly.

The role of WMS: The brain of picking optimization

None of these technologies can reach their full potential without a central conductor: the Warehouse Management System (WMS). Indeed, warehouse management software is much more than just an inventory management tool ; it's the brain that drives and optimizes all operations.

How does a WMS platform transform your logistics flows?

A WMS solution acts as the central nervous system of your warehouse. In picking, it plays a multifaceted role:

• Real-time inventory management: It ensures that the theoretical stock status corresponds to the physical reality, thus avoiding picking shortages (picking up a product that is no longer in its location). This is the basis of good inventory management.
• Organization of preparation waves: It intelligently groups orders (by destination, by product type, by urgency) to optimize picking rounds.
• Picking path optimization: It calculates the shortest possible route for each picker to collect all the items on their list, avoiding unnecessary back-and-forths. Proper optimization can reduce distances by more than 20%.
• Technology management: The WMS sends instructions to Pick-to-Light and Voice Picking systems or coordinates the fleet of mobile robots.

Without a WMS, investing in automation is like buying a race car without having a driver.

The art of slotting and ABC ranking for optimized journeys

One of the levers activated by the WMS is the optimization of storage locations, or "slotting" . The principle is simple: place the right products in the right place.

To do this, the WMS relies on the ABC classification method:

• Class A: Products with the highest turnover (approximately 20% of references, which represent 80% of sales). These products must be placed in the most accessible locations, near packaging areas, at eye level to minimize effort.
• Class B: Medium rotation products.
• Class C: Low-rotation products, which can be stored in less accessible areas.

A WMS can continuously adjust this slotting based on seasonality and sales trends, ensuring that picking routes always remain as short as possible. It also manages replenishment picking, i.e., the transfer of products from bulk storage areas to dedicated picking locations to avoid stockouts.

Checklist: Choosing and integrating the right WMS solution

Choosing WMS software is a strategic project. Here are the key steps to avoid making a mistake:

1. Analysis of the existing situation:

• Map your current logistics flows in detail (receiving, storage, preparation, shipping).
• Identify pain points, bottlenecks and sources of errors.
• Quantify your current volumes and anticipate your growth in 3-5 years.

 2. Definition of functional needs:

• List all the features you need: path optimization, ABC management, compatibility with picking technologies, safety stock management, etc.
• Involve operational teams in drafting these specifications. They are the end users.

3. Market research and selection:

• Identify WMS platform vendors that specialize in your industry.
• Request personalized demonstrations based on your real-life scenarios.
• Check customer references and, if possible, visit a warehouse that uses the solution.

4. Integration and deployment:

• Ensure the WMS's ability to interface with your other systems (ERP, TMS ).
• Plan deployment carefully to minimize impact on ongoing operations.
• Plan for a rigorous testing phase before final launch

5. Training and support:

• Integrating a WMS is a change management project. Training and supporting your teams are key to the project's adoption and success.

Measure to progress: Key Performance Indicators (KPIs) for picking

We only improve what we measure." Automation and optimization via a WMS must result in concrete and quantifiable gains. Here are the essential indicators to monitor to manage the performance of your order preparation.

Speed: Productivity and cycle time

• Productivity per picker: This is the most common KPI. It is measured by the number of order lines picked per hour per operator. Automation can boost this indicator (+20 to 50%).
• Picking cycle time: This is the total time that elapses between the issue of the picking slip and the completion of order picking. It measures the overall agility of your process.

Quality: The preparation error rate

This is the crux of the matter. It measures the percentage of order lines containing an error (wrong product, wrong quantity).

• Calculation: (Number of lines with error / Total number of lines prepared) x 100.
• Objective: Aim for a rate below 0.1%. Automated systems such as voice picking or goods-to-man can achieve rates close to 0.01%.

Each percentage point gained on this KPI translates into substantial savings on non-quality costs ( return transport , reprocessing, customer service, etc.).

Cost: Cost per order line

This indicator summarizes the overall efficiency of your picking. It includes all costs associated with preparation (labor, equipment depreciation, consumables, etc.) and divides them by the total number of lines prepared.

• Calculation: Total preparation costs / Total number of lines prepared.
• Objective: To reduce it continuously. Automation, despite the initial investment, has a direct and massive impact on reducing this cost in the medium and long term.

These KPIs should be tracked in real time via dashboards powered by your WMS, to enable warehouse managers to make quick and informed decisions.

Automation, an essential lever for your supply chain

Picking is no longer a costly and complex inevitability. It has become a strategic function that, when properly optimized, can become a differentiating factor in your market.

Automation, whether through pick-to-light, voice picking, or automated mobile robots (AMR), offers enormous gains in productivity and accuracy. But these technologies are only tools. Their true power is unleashed when orchestrated by warehouse management software (WMS), which optimizes every decision, from the product's location in the inventory to the path taken by the picker.

Investing in picking automation means investing in customer satisfaction, reducing operational costs, and increasing your company's competitiveness. It's the cornerstone of warehouse management and a decisive step toward Warehouse 4.0.

Interested in evaluating the potential of automation for your warehouse? Discover how our EGO WMS solution can transform your logistics.

Contact us for a personalized diagnosis.

FAQ: Everything you need to know about picking

What is the first step to improving your picking without investing heavily?

The first step is often organizational. Before any technology, make sure your warehouse is well organized. Set up an ABC classification for your products and organize your storage accordingly (the "slotting" method). Using inventory management software or a WMS to optimize picking lists can already reduce distances traveled by 10 to 20%.

Will automation eliminate order picker jobs?

No, it transforms their role. In "Goods-to-Man" systems, for example, the most physical and repetitive tasks (walking) are eliminated. The operator focuses on higher value-added tasks: precision picking, quality control, packaging. The role evolves into that of a system pilot, which is less arduous and more skilled.

How long does it take to pay off a picking automation project?

Return on investment (ROI) varies greatly depending on the technology chosen and the size of the warehouse. For systems like Voice Picking or Pick-to-Light, the ROI is often seen between 12 and 24 months . For heavier systems like AMR robots , the investment is more significant, but because the productivity gains are much higher, the ROI is generally between 3 and 5 years .

Can we combine several picking technologies?

Absolutely. It's even a very relevant approach. A warehouse can use a "Goods-to-Man" solution with mobile robots for its Class A (high-turnover) products, Voice Picking for Class B and C product aisles, and a simple manual process for very large or very slow-moving items. It's the role of the WMS platform to manage this heterogeneity and assign the right task to the right resource.