What Influences Retail Manual Pick Rates?

Ecommerce has become one of the fastest growing sectors within the supply chain, making pick rates key. With this growth each business faces a number of challenges, not just scaling up the operation to cope with demand, but also investing in equipment that can adapt as the process changes and improve the operation to make savings wherever possible.

The right warehouse fulfilment plan will not only improve productivity but will also make the whole operation more efficient. However any plan has to take into account a number of factors. Without the right equipment designed for your applications to help achieve the above, implementing the right WMS, tackling productivity or perhaps outsourcing the picking to a 3PL can’t be looked at until the hands on ‘’Picking’’ operation is defined, yet in many cases businesses will look at ‘’Off the shelf solutions’’ instead of a’’ tailor made solution’’, that’s is not only right for the current process but can adapt as and when the fulfilment process changes in the future. And in many cases, this can also take place towards the end of the planning process.

When we look for IT solutions such as WMS, or even the building we occupy how often is the right solution available without some changes? But more importantly how often are today’s requirements the same as those in two or even three years ago? Obviously one of the most important areas we have to consider is order fulfilment, what impacts our output and how this can it be improved. Can time be saved in areas, and thus reduce waste (time or material) Aside from the equipment used the wellbeing of staff has to be a key consideration after all ‘’A happy worker is a productive worker’’.

Speaking to a wide range of retail companies any improvements are the key to achieving profitability and in some cases saving just 2 seconds on a picking operation can have financial benefits to a business , obviously this is dependent on the number of picks carried out, but how many businesses do not want to grow and increase? So what items of equipment can we identify as the ones that will require the most changes over the years and what are the factors influencing change. Take for instance a picking trolley, how difficult is it to move when fully loaded, how does this impact on pick route times, can the picker load all product onto the trolley, are the shelves at the right height, is the handle to move the trolley at the right height for the operator, does the picker need steps to pick items occasionally?

Picking /Packing stations, how many items are required to complete the process? PC, Label printer, boxes, envelopes, protective packaging, how long will the operator have to stand at station, is the work surface the correct height, and are all the items within easy reach and easy to locate? Custom built solutions designed to take the all the above into account and are the obvious solution to answer many of these questions, ‘’Aren’t they expensive compared to off the shelf?’’ Yes is the quick answer, however when you look at a flexible solution that can adapt as your process/workload changes the ROI is unquestionable with so many businesses having to either ‘’Make do’’ or worse still scrap their equipment and start again it does make custom flexible solutions the unequivocal choice to the issues faced not just in E-procurement order fulfilment, but also the far wider order picking market place.

Flowstore offer a wide range of custom built applications into market sectors looking find the right solution that will stand the test of time and adapt as the demand on the supplier changes with the market place, put simply ‘’Smart solutions that work ‘’ With a dedicated team who will visit site understand your process to offer the best solutions.

Improving Manual Ecommerce Picking

Ecommerce over the last three years has become one of the fastest-growing sectors within the supply chain. With this growth, businesses faces a number of challenges, not just scaling up the operation to cope with demand, but also investing in equipment that can adapt as the process changes and improve the operation to make savings wherever possible.

The right warehouse fulfilment plan will not only improve productivity but will also make the whole operation more efficient. However, any plan has to take into account a number of factors.

Without the right equipment designed for your applications to help achieve the above, implementing the right WMS, tackling productivity or perhaps outsourcing the picking to a 3PL can’t be looked at until the hands-on picking operation is defined, yet in many cases businesses will look at off-the-shelf solutions instead of a tailor-made solution that’s not only right for the current process but can adapt as and when the fulfilment process changes in the future. In many cases, this can also take place towards the end of the planning process.

When we look for IT solutions such as WMS or even the building we occupy, how often is the right solution available without some changes? But, more importantly, how often are today’s requirements the same as those two or even three years ago?

Obviously one of the most important areas we have to consider is order fulfilment, what impacts our output and how this can be improved. Can time be saved in certain areas, and thus reduce waste (time or material)? Aside from the equipment used, the wellbeing of staff has to be a key consideration. After all, a happy worker is a productive worker.

Speaking to a wide range of retail companies, any improvement can be key to achieving profitability;  in some cases, saving just two  seconds on a picking operation can have financial benefits to a business. Obviously, this is dependent on the number of picks carried out, but how many businesses do not want to grow?

Right Equipment for Ecommerce

So what items of equipment can we identify as the ones that will require the most changes over the years and what are the factors influencing change? Take, for instance, a picking trolley; how difficult is it to move when fully loaded, how does this impact on pick route times, can the picker load all product onto the trolley, are the shelves at the right  height, is the handle to move the trolley at the right height for the operator, does the picker need steps to pick items occasionally…?

Picking/packing stations: how many are required to complete the process? PC, label printer, boxes, envelopes and protective packaging. How long will the operator have to stand at the station? Is the work surface the correct height, and are all the items within easy reach and easy to locate?

Custom-built solutions designed to take the all the above into account are the obvious solution to answer many of these questions. In response to the question “are they expensive compared to off-the-shelf?” the quick answer is yes. However, when you look at a flexible solution that can adapt as your process/workload changes, the ROI is unquestionable. With so many businesses having to either make do or – worse still – scrap their equipment and start again, it does make custom flexible solutions the unequivocal solution to the issues faced, not just in Eprocurement order fulfilment, but also the far wider order picking market place.

Flowstore offers a wide range of custom-built applications into market sectors looking find the right solution that will stand the test of time and adapt as the demand on the supplier changes with the market place. Put simply, it says its provides “smart solutions that work” with a dedicated team who will visit your site, understand your processes, and try to offer the best solutions.

 

Toy Story for Packaging

Constraints to business expansion, presented by manual packing, lead one international logistics business to invest in fast, fit-to-size automated packaging technology. Established in 2015, Global Freight Management Hersden Ltd is a highly successful international logistics business. Having at the outset secured the Warehousing and Logistics Contract for iconic toy and hobbies brand, Hornby Hobbies, the business has gone on to win a steady stream of clients across the mobile phone, sports equipment and organic food sectors.

From a 120,000 sq ft warehouse in Hersden, Kent, the global logistics services company picks, packs and despatches orders to both trade customers and direct to consumers, across the world. However in 2020, with the explosive growth of ecommerce, the management team quickly came to realise that their highly manual packing operation was a constraint on further expansion of the business.

“We were limited by the fact that there were only so many people that you could get to work in a given space, for so many hours, to pack product,” says, Will Todd, Director and part owner of Global Freight Management Hersden. “We realised that we needed to introduce a level of automation to our packing processes if we were to gain the additional capacity required to take on new clients and develop the business.”

But, for their largest client, Hornby Hobbies, the integrity and quality of the outer packaging was of critical importance, as many of their highly sought after toys and models are purchased by enthusiasts and discerning collectors that seek to retain the original product packaging in mint condition for twenty years or more. A crumpled corner or a scratch to the varnish can be a big issue.
Important considerations for the business were: Could automation deliver the precision and care needed to ensure full protection of the product? And would automation deliver the speed, throughput and productivity levels required to future proof the business?

The solution came in the form of Quadient’s CVP Impack; an advanced automated fit-to-size packaging system, capable of tailor making 500 individual cardboard packages per hour. Will Todd explains: “I read about the CVP Impack in the trade press. It sounded impressive, so I went to see one in operation and realised it was the way to go.”
At the end of July 2020 Quadient’s engineers delivered and installed a CVP Impack automated packaging system, complete with a twin feed for both 600 and 1000 mm cardboard to minimise off-cut waste – the first application of a twin feed CVP Impack in the UK. Will Todd says, “Quadient gave us a delivery date earlier than we were expecting. The machine was unloaded and installed, and within a day perfect boxes were being produced.”

Quadient’s CVP Impack is unique in that it has the potential to construct bespoke individual cardboard boxes to the exact size of an ordered item at the rate of up to of 500 boxes per hour – combining multiple items, as required.

The CVP Impack measures, constructs, tapes, weighs and labels each parcel in one seamless process. The operator simply places the item(s) to be packed onto the machine and scans the order. The system identifies the order and automatically conveys the items to a 3D scanner to measure and calculate the minimum box size required. The cardboard is then cut and folded to create a snug fit around the goods and tape is applied on just two sides to secure the box. Then an in-line scale checks the weight against the order and, finally, the box is automatically conveyed to a label printer where a carrier compliant label is created and applied. The whole process, from start to finish, takes just thirty seconds with a custom made box configured every seven seconds.
“It’s a fabulous piece of kit. It does exactly what was promised. It packs products in the most economically, environmentally friendly and protective way – at high speeds. The packages are perfect for shipping around the world,” says Will Todd.

He points out that although their key reason for investing in the CVP Impack was extra packaging capacity to expand the business, there were several other important benefits too.
“As we are shipping out every order as a box made precisely to the optimum size for the order, we are now using less cardboard – probably around 30% less – which is good from both an environmental and cost view point,” says Will Todd. “And as the boxes are right-sized, that means fewer pallets of boxes being shipped, less lorries on the road and lower emissions – which again brings cost savings.”

The CVP Impack has also freed up labour resources for other tasks, giving greater flexibility across warehouse processes – all part of the business expansion plan.
Will Todd is enthusiastic about the machine’s capabilities and the potential it offers the business. “It’s performing brilliantly. You can’t get much faster in terms of packaging performance and that gives us the capacity to take on more clients.”

More on Quadient’s fit-to-size automated packaging solutions at https://packagingbyquadient.com

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