Paving the path toward automation systems is a critical step that organizations should prioritize. Automating workflows represents the first step toward achieving a fully automated warehouse. This transformation requires minimal investment while being simple and fast to implement, effectively reducing inefficient processes and streamlining operations to ensure maximum value from every movement. In this episode, we will examine examples of optimizing picking route workflows.
For most warehouses, labor costs constitute the largest expense component, with some facilities experiencing costs as high as 70%. Within this figure, picking and packing operations account for up to 50%. Motion waste represents one of the most significant hidden costs—inefficient movement of warehouse personnel. When a worker takes 10 steps to complete a task that could realistically be accomplished in just 3 steps, this constitutes waste. This problem does not stem from inefficient workers but rather from inefficient processes. Therefore, it becomes the warehouse manager's responsibility to create working environments and design processes that enable workers to achieve greater efficiency.
Optimizing picking routes serves as one method to reduce operational costs. This process begins with studying the warehouse layout and typical picking routes, followed by designing new, more streamlined and efficient pathways. Many warehouses have incorporated technology to assist with picking routes, such as smartphones that not only contain the list of items to be picked but also help determine the route to the next item based on the worker's current position.
Some warehouses employ one of the most powerful and popular methods for finding optimal routes through Ant Colony Optimization algorithms. This method derives its name from ant behavior. Initially, only a few ants leave the colony to search for food, dispersing randomly in various directions while secreting pheromones along their paths for other ants to follow. When food sources are discovered—which may actually be the same location—the fastest route will contain higher concentrations of pheromones compared to other paths. As more ants emerge from the colony and travel along the fastest route to reach the food source, the process of transporting food back to the colony becomes increasingly efficient.
Warehouse managers can apply this same principle to picking route planning. Initially, workers are deployed to walk toward targets in different directions while timing their movements. Those following the optimal route will complete their tasks first. Conversely, route optimization can also be applied to inbound receiving processes. Optimizing inbound receiving routes positively impacts overall warehouse management operations, such as faster product placement, reduced opportunities for theft, damage, or loss from items being left in receiving areas for extended periods. Additionally, efficient inbound routes contribute to faster outbound picking processes as well.
Join us for the final episode of "Preparing Before Committing to Automation Investment EP.4" covering Step 3: Evaluating the cost-effectiveness of automation system investments. Coming next.
