The Impact of Automating the Picking Zone on Fulfillment Center Bottlenecks

Automating picking in a fulfillment center is a significant step towards improving efficiency, reducing errors, and speeding up order processing. However, while automation alleviates bottlenecks in the picking zone, it shifts the problem downstream, particularly at packout. This shift occurs because the increased speed and volume of items moving from the picking zone can overwhelm the capacity of the packing zone, leading to delays, inefficiencies, and errors in the final stages of order fulfillment.

In this article, we discuss the downstream impact of automating the picking process, and what strategies and solutions are available to eliminate the problem.

The Downstream Impact: Packing Zone Bottlenecks

Automating the picking zone with either goods-to-person solutions, such as automated storage and retrieval systems (ASRS), or autonomous mobile robots (AMRs), enables faster retrieval of items, higher throughput, and reduced labor requirements. However, this can create a situation where the packing zone becomes the new bottleneck, as it struggles to keep pace with the accelerated inflow of items. This bottleneck can cause delays in order processing, leading to damaged goods, missed shipping deadlines, increased labor costs, and dissatisfied customers.

Packing is a labor-intensive process that requires careful attention to detail. Workers must select the appropriate materials, ensure that items are properly protected, and prepare packages for shipment. If the packing zone is not optimized to handle the increased capacity, the entire fulfillment process can grind to a halt.

Strategies for Optimizing the Packing Process

To address the bottleneck at packout, fulfillment centers must implement strategies to streamline and optimize the packing process. Here are a few effective strategies:

1. Cartonization and Right-Sizing Shipping Cartons
   Cartonization is the process of selecting the optimal carton (or mailer) size for a specific order based on the items being shipped. Cartonization software automatically analyzes the dimensions and weight of the items in an order to recommend the most appropriate carton. This not only reduces the amount of void fill required but also minimizes shipping costs by reducing the overall package size.

2. Implementing Automated Packing Stations
   Automating the pack station with on-demand packaging machines, for example Packsize, can significantly increase the efficiency of the packing process. These systems make right-sized cartons for every order.
   

   Integrating cartonization software with on-demand packaging solutions can expedite the process by pre-building cartons prior to the physical packing step. By reducing the time and labor required for packing, these systems can help alleviate bottlenecks in the packing zone.
   

3. Balancing the Workflow
   Another effective strategy is to balance the workflow between the picking and packing zones. This can be achieved by adjusting the speed of the picking automation or by introducing a buffer zone where items can be temporarily stored before being sent to the packing area. This buffer zone can help smooth out the flow of items, preventing sudden surges that can overwhelm the packing zone.
   

4. Training and Cross-Training Workers
   Ensuring associates in the packing zone are well-trained and capable of handling a variety of tasks is crucial for maintaining efficiency. Cross-training associates to perform both picking and packing tasks can also provide flexibility, allowing workers to be shifted between zones as needed to manage fluctuations in workload.

Conclusion

While automating picking in a fulfillment center offers many benefits, it is essential to consider the downstream impact on other zones. By implementing strategies such as cartonization, on-demand packaging, workflow balancing, and cross-training, fulfillment centers can optimize the packing process and prevent new bottlenecks from emerging. These strategies not only improve efficiency but also enhance the overall customer experience by ensuring that orders are processed and shipped quickly and accurately.