Warehouses are constantly evolving, and goods-to-person systems are at the forefront of this transformation. These innovative solutions are reshaping how we approach order fulfillment and inventory management.
At G2P Robots, we’ve seen firsthand how the right goods-to-person system can dramatically boost efficiency and accuracy in warehouse operations. Choosing the perfect system for your specific needs, however, can be a complex task.
What Are Goods to Person Systems?
Goods to Person systems transform warehouse operations by automating the movement of inventory into, within, and out of warehouses to customers with minimal human assistance. This innovative approach eliminates the need for employees to traverse aisles, significantly reducing travel time and enhancing efficiency. At G2P Robots, we have observed the substantial impact these systems have on productivity and accuracy in various warehouse environments.
The Mechanics Behind Goods to Person Systems
Goods to Person systems employ automated technology to retrieve and transport items to stationary picking stations. This process reverses the traditional warehouse model, where workers move to locate products. The implications of this simple concept for warehouse efficiency are profound.
In conventional warehouses, pickers often spend up to 60% of their time walking between locations. Goods to Person systems effectively eliminate this wasted time. One client reported a 40% increase in picking speed after implementing a Goods to Person solution (a significant improvement in operational efficiency).
Concrete Advantages of Goods to Person Systems
The benefits of Goods to Person systems extend well beyond time savings. Here are some tangible advantages we have observed:
- Accelerated Picking Rates: Some Goods to Person systems achieve picking rates exceeding 1,000 lines per hour, a marked improvement over manual methods.
- Optimized Space Utilization: Vertical storage in Goods to Person systems can optimize vertical space, reallocating valuable floor space back to manufacturing.
- Enhanced Accuracy: The reduction in human movement and integration of verification technologies can lower error rates to less than 0.1%.
- Improved Worker Safety: The decreased need for movement significantly reduces the risk of accidents and repetitive strain injuries.
- Superior Inventory Control: Real-time tracking capabilities of Goods to Person systems can improve inventory accuracy rates to 99.99% with efficient pick and put validations.
Leading Goods to Person Technologies
Several technologies power modern Goods to Person systems:
- Vertical Lift Modules (VLMs): These systems efficiently use vertical space, storing items in trays that are automatically retrieved and delivered to the operator.
- Horizontal Carousels: Ideal for smaller items, these systems rotate horizontally to bring products to the picker.
- Autonomous Mobile Robots (AMRs): These robots independently navigate warehouse floors, transporting mobile storage units to stationary pickers.
- Shuttle Systems: For high-density storage, shuttle systems use autonomous vehicles to retrieve totes or cartons from deep lane racking.
Each of these technologies offers unique strengths, and the optimal choice depends on factors such as warehouse layout, product characteristics, and order profiles. A thorough analysis of these factors is essential to recommend the most suitable Goods to Person solution for each unique warehouse environment.
As we move forward, it’s important to consider the key factors that influence the selection of the right Goods to Person system for your specific needs. The next section will explore these critical considerations in detail, helping you make an informed decision for your warehouse operations.
How to Select the Ideal Goods to Person Systems
The physical characteristics of your warehouse determine the most suitable Goods to Person system. A warehouse with high ceilings might benefit from Vertical Lift Modules (VLMs), which significantly reduce the floor space needed compared to traditional shelving systems by maximizing vertical storage capacity. A facility with a larger floor area might suit horizontal carousels or Autonomous Mobile Robots (AMRs) better.
Consider your warehouse’s existing layout and potential structural limitations. For example, low ceiling height might rule out VLMs, making a shuttle system that maximizes horizontal space a better choice.
Analyzing Product and SKU Profiles
Your inventory nature influences the choice of Goods to Person system. Warehouses with a high variety of SKUs often benefit from systems like Vertical Lift Modules and Vertical Carousel Modules, which are two types of automated storage and retrieval systems suited for different applications. A pharmaceutical distributor implemented a VLM system that increased their picking accuracy to 99.9% while handling over 5,000 different SKUs.
Product characteristics (size, weight, and fragility) also play a role. Heavy or bulky items might require robust shuttle systems, while smaller, lighter products could be managed efficiently with carousel systems.
Evaluating Order Profiles and Throughput Requirements
Your order volume and picking requirements are key factors in selecting the right Goods to Person system. High-volume operations with consistent demand patterns might benefit from highly automated solutions like shuttle systems or AMRs. These systems can handle thousands of picks per hour, significantly boosting productivity.
For operations with more variable demand or lower volumes, a less capital-intensive solution like a horizontal carousel might be more appropriate. Some clients achieve a 200% increase in picking speed with these systems, even in moderate-volume environments.
Consider peak periods and seasonal fluctuations. A flexible system that scales up during busy times can be invaluable. AMRs offer the advantage of easy scalability, allowing warehouses to add or remove units as needed.
Calculating ROI and Budget Considerations
While the upfront cost of Goods to Person systems can be significant, the long-term ROI often justifies the investment. Look beyond the initial price tag and consider factors like labor savings, increased accuracy, and improved space utilization.
Perform a comprehensive cost-benefit analysis, factoring in not just the purchase price, but also installation costs, ongoing maintenance, and potential productivity gains. For example, labor costs and savings are easy to calculate, but space savings from a goods-to-person system, financial benefits of improved service levels, and other factors should also be considered.
Ensuring Seamless Integration
The ability of a Goods to Person system to integrate with your existing warehouse management system (WMS) and other technologies is paramount. A system that can’t communicate effectively with your WMS can negate many of its potential benefits.
Some clients had to overhaul their entire WMS to accommodate a new Goods to Person system, leading to unexpected costs and delays. To avoid this, assess the compatibility of potential Goods to Person solutions with your current systems early in the selection process.
Additionally, consider the scalability of the integration. As your business grows, you’ll want a system that adapts and expands without requiring a complete overhaul of your technology stack.
The selection of the right Goods to Person system involves multiple factors. A thorough evaluation of these elements will lead you to a solution that drives significant improvements in your warehouse efficiency. In the next section, we’ll explore popular Goods to Person technologies and their specific advantages to help you make an informed decision.
Which Goods to Person Technologies Will Revolutionize Your Warehouse?
Vertical Lift Modules (VLMs) transform warehouses with high ceilings and limited floor space. These systems can save up to 90% of the floor space compared to conventional storage. VLMs excel in environments with a high SKU count and smaller items. A pharmaceutical distributor implemented VLMs and cut picking time by 65% while managing over 10,000 SKUs.
VLMs work best for slow to medium-moving items. They provide ergonomic benefits by delivering items at an optimal height, which reduces worker fatigue and potential injuries. However, they may not suit very large or heavy items (typically limited to around 1,000 pounds per tray).
Horizontal Carousels: Small Item Picking at Lightning Speed
Horizontal carousels excel in environments with high-volume, small-item picking. These systems achieve pick rates of up to 550 lines per hour, making them perfect for e-commerce fulfillment centers. When integrated with pick-to-light systems, they boost accuracy to 99.9%.
An electronics retailer implemented horizontal carousels and doubled their picking speed. However, these systems need more floor space than VLMs and don’t work as well for larger items or warehouses with varied product sizes.
Autonomous Mobile Robots: Adapt and Scale with Ease
Autonomous Mobile Robots (AMRs) offer unmatched flexibility in warehouse operations. These robots navigate dynamically, adapting to changing warehouse layouts and peak seasons. AMRs suit operations with fluctuating demand or those aiming to automate processes gradually.
AMRs can operate continuously and tirelessly, significantly boosting warehouse efficiency and productivity. They handle a wide range of payload capacities (from small items to entire pallets), making them versatile across various industries.
However, AMRs require significant initial investment in both hardware and software infrastructure. They also need regular maintenance and updates to operate at peak efficiency.
Shuttle Systems: Dense Storage Meets Rapid Retrieval
Shuttle systems shine in high-density storage environments, particularly for operations dealing with large volumes of similar-sized totes or cartons. These systems achieve high throughput rates.
An automotive parts distributor implemented a shuttle system and increased storage density by 40% while reducing order fulfillment time by 60%. Shuttle systems work best for operations with a high volume of SKUs and consistent demand patterns.
However, shuttle systems rank among the most capital-intensive Goods to Person solutions and require careful planning to align with long-term business goals. They may not suit operations with highly variable product sizes or those requiring frequent reconfiguration.
When choosing between these technologies, consider your specific operational needs, warehouse constraints, and growth projections. G2P Robots offers all these Goods to Person solutions and provides expert guidance on which technology (or combination of technologies) will best suit your unique requirements. Our team conducts thorough analyses of operations to recommend tailored solutions that optimize warehouse efficiency and drive long-term ROI.
Final Thoughts
The selection of an appropriate goods-to-person system will transform your warehouse operations. Various factors influence this decision, including warehouse layout, product characteristics, and order volumes. Each system type offers unique advantages that address specific warehouse needs.