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 impacts the entire value chain : customer returns, dissatisfaction, reshipping costs, loss of trust…

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 about by automation.

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

So, ready to build the warehouse of the future?

Picking: The strategic heart of the warehouse

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

What is picking in logistics?

Picking, or "collecting" in French, is the process of gathering items stored in the warehouse to fulfill customer orders . It is the first concrete step in order execution.

The basic process seems simple:

1. Receipt of the picking list.
2. Operator moves to the location of the item.
3. Removing the correct amount of product.
4. Place the item in a container (package, bin, order picking cart).
5. Validation of the operation and progression to the next article.

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

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

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

The consequences of inefficient picking are direct and measurable:

• Increased operating costs: More time spent per order means more manpower required.
• Slowdown in logistics flows: A bottleneck in picking 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.

Effective logistics management begins with a 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 order 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 picking station where the operator simply retrieves the necessary items. This approach, central to automation, drastically reduces movement 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 leans heavily towards "Goods-to-Man".

Comparative analysis of picking automation technologies

Picking automation is not a one-size-fits-all solution, but rather a range of technologies with distinct strengths and weaknesses. The best choice for your warehouse will depend on your specific circumstances.

The 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 pick. The operator simply follows the light, picks the product, and presses a button to confirm.

Benefits :

• Drastic reduction in errors: Visual guidance is intuitive and limits the risk of confusion. Accuracy rates exceeding 99.5% are observed.
• Increased productivity: Eliminates the time spent reading paper purchase orders and searching for their location. Productivity gains can reach up to 40%.
• Quick start-up: Training 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. Modifying the warehouse layout or adding new items can be complex and costly.

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

Voice Picking: Hands-free efficiency

With Voice Picking, the operator is equipped with a headset and microphone connected to a handheld terminal, which is itself connected to a Warehouse Management System (WMS). The system verbally dictates instructions : where to go, which product to pick, and in what quantity. 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 their picking and driving movements, which improves safety and ergonomics.
• High accuracy: The confirmation dialogue and control 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 SKUs, refrigerated or frozen environments (where handling paper or screens is difficult).

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

This is cutting-edge technology. The operator wears smart glasses (augmented reality glasses) that display all the necessary information directly in their field of vision : directional arrows, highlighted product location, quantity to take, and a product image. Order confirmation can be done via voice command or 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 anomalies, and guiding through complex processes.
• Maximum accuracy: 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 extended periods may require an adjustment period.

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

Autonomous Mobile Robots (AMRs): The agility of "Goods-to-Man"

Here, we enter another dimension: "Goods-to-Man." Instead of the operator moving around, autonomous mobile robots (AMRs) retrieve the required products from the shelves and bring them directly to the picking station . The operator remains stationary. A light system (similar to Pick-to-Light) indicates on the shelf which product to pick. Once the task is complete, the robot returns to the shelf to restock, and another arrives with the rest of the order.

Benefits :

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

Disadvantages:

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

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

The role of the WMS: The brain of picking optimization

None of these technologies can reach their full potential without a conductor: the Warehouse Management System (WMS). Indeed, warehouse management software is much more than a simple inventory management tool ; it is the brain that directs 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 the context of order picking, its role is multifaceted:

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

Without a WMS, investing in automation is like buying a race car without 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 achieve this, the WMS relies on the ABC classification method:

• Class A: High-turnover products (approximately 20% of SKUs, representing 80% of sales). These products should be placed in the most accessible locations, near packaging areas, at eye level to minimize effort.
• Class B: Products with medium turnover.
• Class C: Slow-moving 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 remain as short as possible. It also manages picking replenishment, meaning the transfer of products from bulk storage areas to dedicated picking locations to prevent stockouts.

Checklist: Choosing and integrating the right WMS solution

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

1. Analysis of the current situation:

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

 2. Definition of functional requirements:

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

3. Market research and selection:

• Identify WMS platform vendors specializing in your industry.
• Request customized 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 has the ability to interface with your other systems (ERP, TMS ).
• Plan the deployment carefully to minimize the impact on ongoing operations.
• Plan for a rigorous testing phase before the final launch

5. Training and support:

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

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

"You can only improve what you measure." Automation and optimization via a WMS must translate into concrete and quantifiable gains. Here are the essential indicators to track 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 in the number of order lines picked per hour per operator. Automation can dramatically increase this metric (+20 to 50%).
• Picking cycle time: This is the total time that elapses between the issuance of the picking slip and the completion of the 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 make it possible to achieve rates close to 0.01%.

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

The cost: The cost per order line

This indicator summarizes the overall efficiency of your picking process. It incorporates all costs associated with order 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 must be monitored in real time via dashboards powered by your WMS, in order 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 which, when properly optimized, can become a differentiating factor in your market.

Automation, whether through Pick-to-Light, Voice Picking, or Mobile Robots (AMR), offers enormous gains in productivity and accuracy. But these technologies are merely tools. Their true power is unleashed when orchestrated by a Warehouse Management System (WMS), which optimizes every decision, from the product's location in the warehouse to the picker's route.

Investing in automated picking means investing in customer satisfaction, reduced operating costs, and a more competitive business. It's the cornerstone of warehouse management and a crucial step towards Warehouse 4.0.

Do you want to assess 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 massive investment?

The first step is often organizational. Before any technology is implemented, ensure your warehouse is well-organized. Implement an ABC classification system 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 toward that of a system operator, less strenuous and more skilled.

How long does it take to make a picking automation project profitable?

The return on investment (ROI) varies considerably 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 more complex systems like AMR robots , the investment is higher, but the productivity gains are significantly greater, so the ROI is generally between 3 and 5 years .

Can several picking technologies be combined?

Absolutely. It's actually 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 aisles of Class B and C products, and a simple manual process for very large or slow-moving items. It's the role of the WMS platform to manage this heterogeneity and assign the right task to the right resource.