Excess inventory can be a real headache for any industry. In the manufacturing and logistics…
Logistics picking optimization in manufacturing: avoid errors and improve performance
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Picking is one of the most critical operations in the supply chain of any manufacturing company. An efficient and error-free picking process is essential to ensure customer satisfaction, reduce operational costs, and maintain competitiveness in the market.
However, many organizations face significant challenges at this stage, resulting in delays, errors, and ultimately, losses. Below, we will analyze the most common errors in logistic picking in manufacturing, strategies to avoid them, and the picking systems that can transform operational efficiency.
Common Mistakes in the Picking Process
In the manufacturing sector, where efficiency and accuracy are key to success, both are indispensable in the picking process. However, there are several common mistakes that can affect both productivity and customer satisfaction:
📍 Location Mistakes
One of the most common logistics picking errors is selecting the wrong product location. This typically occurs when products are not properly labeled or are stored in a disorganized manner. As a result, operators waste time searching for the correct item, and the risk of selecting the wrong product increases.
Implementing a warehouse management system (WMS) with optimized locations and clear labels will help reduce this type of error. Additionally, an efficient warehouse design can improve visibility and facilitate the location of products.
📝 Inadequate Manual Picking
In manual picking, employees often rely on their memory or paper lists, which can lead to choosing incorrect items, omitting products, or making incomplete deliveries.
Using picking devices such as mobile terminals, barcode scanners, and voice devices helps minimize the risk of human mistake and improves picking accuracy. Automating the process can ensure greater consistency.
📚 Lack of Proper Training
Staff who are not properly trained in the picking process can make mistakes due to a lack of understanding of the correct procedures or how to operate equipment.
Providing continuous training on best picking practices and the use of technological tools ensures that employees operate efficiently, reducing the error rate.
📋 Not Following the Order of Priorities
Sometimes, urgent or high-priority orders are not processed correctly because no specific resources are allocated for immediate attention.
Implementing a management system that allows orders to be prioritized based on urgency and optimizing workflow is essential. Using specialized software to manage priorities and human resources is key to improving efficiency.
📦 Inadequate Inventory Management
Poor inventory control can cause stockouts or an excess of unwanted products, negatively impacting the picking process.
Keeping an updated inventory through real-time monitoring tools is crucial. An efficient WMS system can help make immediate adjustments and improve picking accuracy.
Strategies to Optimize Logistic Picking
Fortunately, picking is a process that can be optimized with a series of strategies that improve each stage. The most effective ones are:
🔄 Implement a Batch Picking System
Batch picking allows multiple orders to be picked at the same time, which is a great strategy to improve efficiency when handling large volumes of products. This allows grouping similar products, avoiding duplication of efforts and downtime.
🤖 Automate the Picking Process
Incorporating automated picking systems, such as robots or automated conveyors, reduces human errors, speeds up the process, and improves product selection accuracy. Additionally, automation is especially useful for high-volume operations and environments with high turnover of inventory.
🏗️ Optimize Warehouse Design
An efficient warehouse design reduces operators’ travel time and minimizes the risk of errors. Ensuring that the most demanded products are easily accessible and distributing items logically based on workflow is crucial.
📡 Use Advanced Technology
Using advanced warehouse management systems (WMS), RFID technology, barcode scanners, and voice picking can increase efficiency and significantly reduce errors. These systems allow real-time traceability and better resource planning.
Picking Systems and Their Benefits
Previously, the picking process was done manually, which carried the risk of delays and errors. Fortunately, there are now systems that allow tasks to be automated, making them more efficient:
🎤 Voice Picking
Voice picking is an advanced technology that allows operators to receive picking instructions through headsets, enabling them to work faster and more accurately with their hands free.
This system increases speed, reduces errors, and improves safety since operators do not have to look at screens or consult physical lists.
📱 RF Picking
RF picking allows operators to use mobile devices to scan products and verify their location and status in real-time.
The goal is to improve inventory accuracy, reduce search time, and increase operational efficiency.
🤖 Automated Picking
Automated picking is one of the most advanced solutions and uses robots and automated systems to select and move products precisely.
Its implementation increases speed, reduces human intervention, and almost eliminates all errors related to picking.
Optimize Your Logistics with AI Río Bravo
Are you ready to optimize your logistic picking process and improve the performance of your manufacturing operation? AI Río Bravo offers advanced logistical solutions such as cross-docking, inventory management, and efficient picking systems to maximize your productivity and reduce errors.
Contact us today and discover how we can help you transform your supply chain!
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