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

Konrad Wolfenstein

5 years ago

Multi Or Picking – Smart Intralogistics Concept – Logistics Strategy

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

In an era of ever-accelerating processes, intralogistics is constantly confronted with growing challenges. Whether it's increasing product variety and order volumes, or the desire for improved order picking, warehouse logistics professionals are constantly searching for new methods to make processes even more efficient and streamlined. But what happens when the warehouse capacity limit is reached? Cross-picking offers a smart and cost-effective solution.

To enable rapid order picking, batch picking has long been the standard practice in modern warehouse systems. However, despite this effective technology, warehouse processes reach their limits as soon as too many orders are received. Until now, affected companies have had only one logical solution to overcome this bottleneck: expanding warehouse capacity with new equipment. However, this is often not possible due to problematic spatial constraints within the warehouse. Furthermore, the frequently expressed concerns regarding the cost-benefit ratio of a new warehouse solution are another argument against expansion.

However, countless studies and practical examples now explicitly confirm the productive effects of the latter. According to these, automated storage systems offer a number of advantages over conventional rack storage systems:

Faster and more precise order picking
Reduced space requirements with increased storage capacity
Energy efficiency and ergonomics
Protection of the items from external influences and theft
More efficient workflows through software control

But what happens when capacity limits are reached despite state-of-the-art warehouse equipment? Here, too, expansion was usually the recommendation from logistics system providers. Many companies are still hesitant due to the cost of the additional equipment.

Improved order picking with cross-picking given the existing infrastructure.

Multi order picking / cross picking infrastructure

To help companies with the problem described, there is a customized cross-picking solution as a smart alternative to costly expansion. This solution increases performance and productivity within the same footprint, without requiring the replacement of existing warehouse equipment. Furthermore, this method can increase productivity by up to 30 percent compared to other batch picking strategies.

The design of the innovative cross-picking station is remarkably simple. The concept involves two rows of lift systems facing each other. An additional double station, with storage areas for batch order collection containers, is positioned between the two picking zones along the entire length of the system. These containers are transported via an integrated conveyor belt. The containers are filled from both sides: firstly, into the containers on the same side, and secondly, crosswise, into the containers of the station installed opposite. This is achieved by installing two counter-rotating chutes above each container. Items placed in these chutes slide to the opposite station, or emerge from it. This effectively doubles the picking performance for batch orders.

Pick-by-Light displays on the central conveyor belt ensure maximum precision in accessing items, informing the warehouse worker how to handle each item: either placing it in the container for his order, onto the chute for the corresponding order at the opposite station, or taking a part from the chute to use for his order.

Using the hoppers, the batch orders are simultaneously supplied with items from the opposite storage units. Consequently, the batch containers no longer need to be moved from one station to another until they are finished. This allows for more picking in less time within the same footprint, while simultaneously minimizing the transport distance of the batch containers. Once an order is fully filled, this is confirmed by a display on each side. The containers are then transported away via the integrated conveyor belt, while new, empty boxes are provided on the 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 system was to be reorganized and made more efficient. The new warehouse was designed to store 22,000 items and make them available to employees or customers as quickly as possible.

The solution consisted of integrating various storage systems and warehouse management software that controls the storage equipment and the entire process from receiving to retrieval. In the warehouse, five vertical storage lifts face each other, with a batch picking station for 2 x 15 containers between them and a central conveyor belt for removing the full containers. Empty containers are delivered via a belt above.

The order pickers are now processing the combined orders for the 15 boxes on their side and the 15 boxes on the opposite side, resulting in the desired acceleration of the processes. Full containers are then automatically transported away, while empty boxes for the next orders are delivered at head height.

The advantages of the solution are obvious: