Optimising picking systems with custom conveyor solutions in modern warehouses

In our modern logistics landscape, customers expect speedy and accurate deliveries, and the efficiency of warehouse picking systems can make or break your customer satisfaction rates. Efficient picking systems play a critical role in increasing order fulfilment speed, ensuring accuracy, and reducing operational costs. As demand grows, traditional picking methods often fall short, and it’s time to seek better solutions. Custom conveyor solutions have emerged as a new approach to ensure operational success. Read on to discover how a custom conveyor solution can help to streamline picking systems, improve accuracy, and ultimately increase customer satisfaction.

The importance of efficient picking systems

Efficient picking systems are the bottom line in achieving swift and accurate order fulfilment. Here’s why:

Order fulfilment speed

In recent years, customer expectations for quick deliveries in the e-commerce space have skyrocketed. Using a custom conveyor system supports a more efficient picking system that makes sure orders are processed quickly, meeting or even exceeding delivery expectations.

Accuracy requirements

Accuracy is top of mind when it comes to picking. If you get it right the first time, you reduce the rate of returns and earn your business a reputation for customer satisfaction. Conversely, mistakes in picking can lead to incorrect orders, resulting in returns, additional labour, and unhappy customers. A well-optimised picking system with automated warehouse picking solutions reduces the margin for error.

Labour costs

Traditionally, picking processes require a substantial amount of manual labour. Moving to a custom conveyor system minimises the need for extensive manual handling, redirecting staff towards more value-added tasks and improving operational efficiency. Overall, this can significantly decrease labour costs.

Limitations of traditional picking methods

Traditional picking methods have served the industry well for years, and many warehouses still rely on them. But as e-commerce becomes more high volume, the limitations of traditional picking methods can impact a business. Here’s an overview of the challenges associated with traditional picking systems:

• Inefficiency: Traditional picking is a labour-intensive task that takes a long time, leading to increased operational costs. Workers must move from one area to another to pick items, leading to slow order processing and increased fatigue.
• High error rates: That increase in fatigue from workers also makes manual picking prone to mistakes, especially in high-volume environments. Even small errors can lead to costly returns, impacting profitability and customer relationships.
• Scalability issues: Traditional picking systems struggle to adapt to growing demands. With larger order volumes, manual systems become increasingly strained, leading to slower processing times and a higher risk of errors.

Custom conveyor solutions for picking

Custom conveyor solutions address the challenges presented by manual picking head-on, streamlining your picking process using automated systems that can be tailored to your warehouse’s specific needs.

Automated warehouse picking solutions use conveyor systems to move products efficiently. The conveyors transport items directly to the picker, cutting down on your workers moving from area to area in the warehouse, and improving processing speeds as a result.

An integrated system between conveyors and the Warehouse Management System (WMS) allows for real-time tracking of inventory and orders. The WMS directs items to the right picker, so that orders are filled accurately and efficiently.

Custom conveyor layouts consider the unique needs of each facility. By analysing the warehouse's size, layout, and product types, a custom conveyor system can be designed to fit specific workflows, to make the most of the space available, and to make the picking process as efficient as possible.

Benefits of custom conveyor systems

Implementing a custom conveyor system in your warehouse can bring benefits that enhance the overall picking system and operations:

Increased speed

With conveyors helping your goods move faster, the time needed for each pick is reduced. This speed carries over to quicker order processing, helping your team to meet tight deadlines while reducing the strain on staff.

Improved accuracy

Automation reduces the opportunity for human error. With conveyors directly transporting goods to designated picking zones, the likelihood of picking mistakes is reduced while order accuracy and customer satisfaction are increased.

Enhanced productivity 

By automating the movement of products, custom conveyor systems allow staff to focus on tasks that add value, like quality control or inventory management, rather than spending a lot of time manually retrieving items.

Implementation strategies

Adopting custom conveyor solutions over traditional manual picking systems may seem like a big change, but with careful planning and execution, it can be simplified. Here are some best practices for a successful implementation:

• Process mapping: Begin your change process by analysing your current workflow to see where there is room for improvement. Process mapping helps visualise the warehouse's operations, to create a targeted conveyor design and integration.
• Technology integration: Make sure that the custom conveyor system is compatible with your existing technologies, such as the WMS. Integration allows for seamless operations, reducing downtime during the switch, and improving ongoing order accuracy.
• Staff training: Properly training employees on the new system is essential. Staff must understand the functions of the conveyor system and how to operate it efficiently to make sure the transition is as smooth as possible.

Future trends in picking systems

New technology is on its way that could revolutionise the future of picking systems. They have the potential to make warehouse operations more efficient, accurate, and even more scalable. Here are some trends to watch:

• Robotics: Autonomous mobile robots (AMRs) are increasingly being used alongside conveyor systems to transport items directly to picking stations. With advanced sensors and mapping technologies, AMRs are flexible, adaptable and ideal for high-volume warehouses.
• Artificial intelligence (AI): AI-powered analytics can predict inventory needs and use that information to design picking routes. By analysing data patterns, AI helps warehouses anticipate demand, streamline picking processes, and reduce inventory holding costs.
• Augmented reality (AR): AR can assist pickers by providing real-time visual aids, showing them the route to specific items and reducing the time spent looking for products. This technology enhances picking accuracy and boosts productivity.

Conclusion

Custom conveyor solutions are vital for improving warehouse picking systems, creating faster and more accurate order fulfilment while reducing costs. By embracing these solutions, warehouse managers can improve their operational efficiency, customer satisfaction, and the bottom line, all in one hit.

For warehouses looking to stay competitive, now is the time to explore the benefits of custom conveyor solutions. Whether you’re aiming to reduce labour costs, enhance accuracy, or speed up order fulfilment, custom conveyors can provide the edge your operations need. At Modular Conveyors Ltd (MCL), we offer a comprehensive range of options, including contract manufacturing and custom-built solutions, ensuring that your needs are always met with precision and efficiency.

Looking for better material handling systems with easy integration? Get a free quote today and discover tailored conveyor solutions for your business with MCL.