As order volumes increase and delivery expectations tighten, operations managers are constantly seeking innovative ways to boost productivity without expanding their physical footprint. Enter cross picking: a game-changing strategy that’s transforming order fulfilment processes across the industry.
What is Cross Picking?
Short Answer – Cross-picking simplifies order fulfilment by letting workers pick items from one area and sort them directly into multiple order containers. This eliminates the need to shuffle containers around, saving time and boosting warehouse efficiency.
Cross picking is an advanced order picking method that significantly enhances the efficiency of traditional batch picking systems. At its core, cross picking allows warehouse operators to fill orders from multiple zones simultaneously, without the need to physically move order totes between zones. This clever approach essentially supercharges batch picking, enabling warehouses to handle larger batch sizes and achieve higher throughput rates within the same floor space.
Key Features of Cross Picking:
• Combines two pick zones into one integrated system
• Utilises face-to-face configuration of storage modules
• Incorporates a central batch station with dual-directional flow racks
• Employs light-directed picking and putting for accuracy
• Enables simultaneous order fulfilment from multiple zones
The Mechanics of Cross Picking
To truly appreciate the innovation of cross picking, it’s essential to understand how it works in practice. Let’s break down the process step-by-step:
- System Setup: Two pick zones, typically comprising Vertical Buffer Modules, Vertical Lift Modules, Vertical Carousel Modules, or Horizontal Carousel Modules, are positioned facing each other. Between these zones is a batch station featuring a side-by-side roller conveyor topped with alternately angled flow racks (slides).
- Order Batching: The Warehouse Management System (WMS) groups orders into batches and releases them for fulfilment, just as in standard batch picking.
- Batch Initialisation: Operators in each zone set up the batch by scanning order totes to associate them with specific batch station locations.
- Picking Process: • Operators start picking in their respective zones. • Light-directed systems guide operators to correct storage locations and indicate required quantities. • Operators confirm picks via the system.
- Cross-Zone Distribution: • When returning to the batch station, operators encounter two levels of put lights:
- Lower lights direct items into order totes within their zone
- Upper lights guide items onto slides for orders in the opposite zone • Operators distribute picked items according to these light instructions, effectively filling orders in both zones simultaneously.
- Order Completion: As orders are filled with items from both zones, put lights signal completion. Operators then move completed order totes to the next processing area.
The Power of Cross Picking: Key Benefits
Cross picking isn’t just a minor tweak to existing systems; it’s a revolutionary approach that offers several significant advantages:
- Doubled Batch Sizes: By enabling simultaneous picking for two zones, cross picking effectively doubles the number of orders that can be processed in a single batch.
- Increased Productivity: Cross picking systems can boost picking productivity by approximately 30% compared to traditional batch picking methods.
- Eliminated Zone Transfers: The need to physically move incomplete orders between zones is eradicated, saving valuable time and reducing the risk of errors or misplacements.
- Enhanced Accuracy: With light-directed picking and putting, cross picking systems maintain an impressive 99.9% order fulfilment accuracy rate.
- Space Optimisation: Higher throughput is achieved within the same warehouse footprint, delaying or eliminating the need for costly expansions.
- Reduced Labour Costs: Increased efficiency means more orders can be processed with the same number of staff, potentially lowering labour costs per order.
- Improved Ergonomics: The face-to-face configuration and slide system reduce the physical strain on operators, potentially decreasing fatigue and injury risks.
Implementing Cross Picking: Considerations and Best Practices
While the benefits of cross picking are clear, successful implementation requires careful planning and consideration:
• Inventory Analysis: Conduct a thorough analysis of your inventory to determine optimal product placement across zones.
• Technology Integration: Ensure your WMS can support cross picking workflows and integrate seamlessly with light-directed systems.
• Staff Training: Provide comprehensive training to operators on the new system and workflows to maximise efficiency gains.
• Performance Monitoring: Implement robust monitoring systems to track key performance indicators (KPIs) and identify areas for continuous improvement.
• Scalability Planning: Design your cross picking system with future growth in mind, allowing for easy expansion or reconfiguration as needs change.
Is Cross Picking Right for Your Warehouse?
Cross picking offers significant benefits, but it’s not a one-size-fits-all solution. Consider implementing cross picking if:
• Your current batch picking system is reaching its capacity limits
• You’re facing space constraints but need to increase throughput
• Your inventory includes a wide range of SKUs that can be logically divided into zones
• You’re looking to improve order accuracy while boosting productivity
• Your warehouse management system can support advanced picking strategies
The Future of Warehouse Efficiency
As e-commerce continues to grow and consumer expectations for rapid delivery intensify, innovative strategies like cross picking will play an increasingly important role in warehouse operations. By embracing this advanced picking method, warehouses can significantly enhance their efficiency, accuracy, and competitiveness in the market.
Cross picking represents a leap forward in order fulfilment technology, offering a powerful solution to the challenges of modern warehousing. As you consider ways to optimise your operations, cross picking deserves serious consideration as a strategy that can deliver remarkable improvements without the need for extensive warehouse expansions or overhauls.
Ready to supercharge your warehouse efficiency with cross picking?
PALLITE’s innovative PIX storage solutions are the perfect complement to this cutting-edge strategy. Our lightweight, customizable units can be easily configured to create the ideal cross-picking setup, maximizing your warehouse space and boosting productivity.
Discover how PALLITE PIX can transform your order fulfilment process:
- Flexible modular design adapts seamlessly to cross-picking layouts
- Lightweight construction allows for easy reconfiguration as needs change
- Sustainable materials align with your eco-friendly warehouse goals
- Customisable sizes ensure a perfect fit for your unique inventory
Don’t let outdated storage solutions hold back your warehouse efficiency. Take the first step towards revolutionising your order picking process today.
