Reducing travel within the warehouse is crucial for improving fulfillment rates, cutting labour costs, and boosting employee satisfaction. No one enjoys mindlessly walking on the warehouse floor due to poor layout and congestion. According to iWMS’s Chief Delivery Officer, Srinivasan Prasanna, here are key strategies to optimise warehouse travel:
- Clear Signage: Ensure good signage throughout the warehouse, so employees are always aware of the aisles and pick areas. Clear signs reduce confusion and streamline navigation, improving overall warehouse efficiency.
- Logical Layout: Design the warehouse layout logically to prevent congestion and narrow aisles. Arrange pick areas according to the planogram of the stores for smoother operations. A well-thought-out layout minimises travel distance and enhances workflow.
- Effective Labeling: Use legible and logical labeling, including QR codes or barcodes, to clearly indicate aisles, levels, locations, totes, and bins. This helps employees identify locations quickly and accurately, reducing search time.
- Organised Receiving Process: Schedule appointments for inbound goods to ensure accurate and timely receipt. Efficient receiving helps with timely inspection and putaway, reducing the need for unnecessary replenishments. Consider cross-docking opportunities to fulfill orders directly from the receiving dock, thereby reducing internal travel.
- Automated Solutions: Implement Automated Mobile Robots (AMRs) and Goods-to-Person systems to minimise travel time between picking zones. Use conveyors to assist with internal goods movement, enhancing overall efficiency.
- Minimise Worker Fatigue: Address worker fatigue by providing cushioned mats at stationary work areas, proper training on lifting and handling, and efficient slotting to place high-velocity items within easy reach (waist-high zones, also known as golden zones). Reducing physical strain can lead to higher productivity and job satisfaction.
- Optimised Picking Strategies: Utilise batch picking to enhance efficiency and reduce travel time. Ensure there are sufficient sort stations to prevent bottlenecks. Batch picking can significantly decrease the distance workers need to travel, improving order fulfillment speed.
- Advanced Technology: Employ technology such as voice picking for hands-free operations and laser beams to highlight pick locations. Always seek ways to minimise unnecessary scans and prompts to streamline picking. Advanced picking technologies can reduce errors and improve speed.
- Efficient Replenishment: Focus on efficient replenishment processes to enable one-pass picking. Streamlining replenishment ensures that stock levels are maintained without excessive travel.
- Establish KPIs: Set key performance indicators (KPIs) to measure space utilisation, pick volumes, pick accuracy, and labour costs. Use collected data for Root Cause Analysis (RCA) with techniques like the 5 Whys to identify and resolve issues for further streamlining. KPIs provide actionable insights for continuous improvement.
By implementing these strategies, your warehouse can achieve greater efficiency, reduce costs, and enhance employee satisfaction. For tailored solutions and expert guidance, reach out to iWMS, a trusted partner of Körber Supply Chain. Our team is ready to help you transform your warehouse operations.
Chief Delivery Officer at iWMS