Warehouse: Order Cross Picking – Intelligent and cost-effective alternative to expanding the warehouse

Published on: February 10, 2021 / update from: April 24, 2021 - Author: Konrad Wolfenstein

Multi Or Picking – Smart Intralogistics Concept – Logistics Strategy

Warehouse Strategist: Multi Order Picking / Cross Picking – Image: Panchenko Vladimir

In times of ever faster processes, intralogistics is constantly confronted with growing challenges. Whether it's the increasing variety of product ranges and query quantities or the desire for better order picking: warehouse logistics companies are constantly looking for new methods to make processes even more effective and lean. But what do you do when the warehouse capacity limit is reached? Cross picking offers the intelligent and cost-effective solution.

In order to be able to pick goods quickly, the batch picking principle has long been established in modern storage systems. But despite this effective technology, the processes in the warehouse reach their limits as soon as too many orders are received. So far, affected companies have only had one logical answer to solve the bottleneck: expanding storage capacity with new equipment. However, this is often not possible due to problematic spatial conditions in the warehouse. Another argument against the expansion are the frequently expressed concerns regarding the cost-benefit ratio of a new storage solution.

However, there are now countless studies and practical examples that explicitly confirm the productive effects of the latter. Accordingly, automated storage systems have a number of advantages over conventional rack storage systems:

• Faster and more precise picking
• Reduced space requirements with increased storage capacity
• Energy efficiency and ergonomics
• Protecting items from external influences and theft
• More efficient processes through software control

But what should you do if the capacity limit is reached despite the most modern storage equipment? Here too, an expansion was usually the recommendation of the logistics system providers. Many companies are still afraid of the cost of additional devices.

Order picking better with cross picking given the given infrastructure

Multi order picking / cross picking infrastructure

To help companies with the problems described, there is an individual cross picking solution as an intelligent alternative to costly expansion. It increases performance and productivity in the same area without having to replace the existing storage equipment. Additionally, this method can increase productivity by up to 30 percent compared to other batch picking strategies.

Setting up the innovative cross picking station is incredibly easy. One concept envisages a lift system in two rows facing each other. Between the two picking zones, an additional double station with areas for the collection containers for batch orders will be placed along the entire length of the system, with transport running via an integrated conveyor belt. The containers are filled from both sides: on the one hand into the containers located on their own side, and on the other hand crosswise into the containers of the station installed on the opposite side. This is done by placing two opposing chutes above each container. Items placed in this slide to the opposite station or arrive from it. The picking performance for collective orders is therefore doubled.

Pick-by-light displays on the central container conveyor ensure the highest precision of access, through which the warehouse worker is informed how to handle the respective item: either he places it in the container of his picking order, on the chute for the appropriate order the opposite station, or he takes a part from the slide to use it for his job.

Using the chutes, the collection orders are simultaneously supplied with items from the storage devices opposite. The batch containers therefore no longer have to be moved from one station to another until they are finished processing. In this way, more is picked in less time on the same area and at the same time the transport distance of the batch containers is minimized. Once an order has been filled, this is confirmed by a display on every page. The containers are transported away via the integrated conveyor belt, while new, empty boxes are provided on a level above.

A manufacturer of special and heavy-duty trailers for trucks decided to centralize its warehouse, which was previously spread across three production sites in France, Spain and Germany. At the same time, the entire intralogistics should be reorganized and made more efficient. The new warehouse should have space for 22,000 items and, if necessary, make them available to employees or customers in the shortest possible time.

The solution consisted of the integration of various storage systems and warehouse management software, which controls the storage devices and the entire process from the storage to the removal of the items. There are five storage lifts facing each other in the warehouse, with a batch picking station for 2×15 containers in between and a central conveyor belt for transporting the full containers away. Empty boxes are provided via a belt above them.

The pickers now process the collection orders for the 15 boxes on their side and the 15 boxes on the opposite side, which leads to the desired acceleration of the processes. Full containers are then automatically transported away, while empty boxes are delivered at head height for the next orders.

The advantages of the solution are obvious:

• No need to purchase new storage systems
• More order picking performance on the same area
• Increase productivity by up to 30 percent
• Picking precision of 99.9 percent
• Time savings through shortened routes