Picking accuracy plays a huge role in any warehousing operation. From the customer's point of view it is vital that they get exactly what they ordered, in the right quantity and in a timescale that suits them. From the company's point of view, accurate inventory levels and order tracking are needed to make the best possible use of ERP and management systems.

In all manual picking operations – especially those involved in small parts storage – there will always be an element of "what if". It is when numerous "what ifs" combine to turn into a major issue that the effects of inaccurate picking begin to take their toll. Incorrect picks leading to incorrect stock levels can really start to have a negative impact unless remedial action is taken. Arguably the best approach is to remove the problem in the first place. This is where pick-to-light systems really pay dividends in terms of both accuracy and speed and the payback can be almost instantaneous; even if it is just in terms of the opportunity costs saved through not having to re pick an order… or find a new customer.

Kardex, the world's leading provider of advanced picking and distribution technology, offers its customers the widest range of pick-to-light technologies, helping to ensure that accuracy levels are in the higher percentiles and picking speeds greatly enhanced. Although the hardware may be a little advanced, the philosophy behind it is remarkably simple. Combine this with an extremely shallow learning curve and, according to Richard Price, business development manager at Kardex: "You can teach anyone to pick hundreds of lines per hour with 99% accuracy – within 10 minutes."

Pick-to-light does exactly what the name suggests; it offers users a visual indication of exactly what should be picked by highlighting the position of the tray, container or tote. On a shelf, which can contain as many as 30 trays – which can also be sub-divided – the advantages are immediately obvious. Removing the ambiguity addresses speed issues just as much as those associated with accuracy.

The visual indication and prompts used in pick-to-light systems can take a number of forms. Starting at the basic level, a simple plain light or LED array can be used to create a small pool of light over a specific tray or tote. Further precision is offered by laser pointers and at the top of the tree is an information matrix that runs across the front of the shelf informing the users of exactly what is needed, in what quantity and from which container. When used in combination, all elements of doubt are removed. Even when used on their own, all offer superior accuracy over a simple visual check.

It is when pick-to-light systems are put to work by advanced picking software such as Kardex's PowerPick suite that the positive effects become even more noticeable. Using the various pick-to-light technologies, the software can tell users the all-important what, where and how many, but its capabilities go far beyond simple location and part-count parameters. Order processing speeds can be enhanced by an order of magnitude, allowing users to give their customers even quicker order turnaround.

Batched order picking allows multiple orders specifying the same part or component to be grouped so users do not have to pay a second visit to the same tray to pick a subsequent order. This is especially effective when processing a large number of orders each with a small number of lines. The data for the multiple orders is combined into a single consolidated order, with the individual counts still segregated, which is then processed as if it were one-pick operation. The data behind the original order is still kept so that confirmation on the host system is still possible.

The next step is to consolidate on a line process, known as CombiPicking within Kardex. In this approach, when the same parts are picked for multiple orders, they are all picked in one step but the part counts are combined into to one large pick. They are then segregated at the time of assignment to the picking container. In this instance a pack-to-light system is used to indicate how many of each component need to go in each container.

Although Kardex's automated storage systems already have the ability to store regularly accessed components – both close to each other and close to the point of picking – shuffling the shelves adds vital seconds onto any order pick. It is for this reason that batch picking and CombiPicking shave even more time off picking times.

Looking at the flipside of the process, light-based pointing systems all deliver significant benefits when it comes to replenishing the storage system as well, with Price proclaiming: "the accuracy of your replenishment has a direct affect on the accuracy of your picking". Working in exactly the same way as pick-to-light, pack-to-light removes all the ambiguity and ensures that all parts are stored in the correct locations. As well as the inherent speed benefits, counting and order checking are also greatly enhanced, making auditing a far simpler and more effective process.

There is no doubt that visual indicators can play a vital role in ensuring far greater picking and packing accuracy and superior picking speeds. Companies would no longer be reliant on individuals having implicit knowledge of the stores operations and all elements of doubt can be removed. In addition, the shallow learning curve means that peaks and troughs in demand that are often addressed by seasonal labour do not necessarily have to result in a drop in picking accuracy. Your mother probably did tell you that it was rude to point, but for the sake of 99%+ picking accuracy I am sure you will agree she will let you off this time.

About Kardex
Kardex is one of the world’s leading manufacturers of automated retrieval, material handling and storage systems. With over 175,000 systems operating around the globe, Kardex delivers solutions that allow world class companies to access their critical parts and documents quickly, efficiently and reliably.
Kardex has operations in 30 countries and employs over 1,000 people. For more information visit www.kardex.co.uk