Problem Solving - Direct Store Delivery - Paperless Voice Picking – Should This Move to Unicorn Status for DSD Operations?

I thought I would discuss the picking process further given the number of comments and questions generated from my last blog entry of a similar topic. This time I would like to discuss some challenges and solutions associated with voice picking in the DSD process flow.

Voice picking basically follows some similar steps, the picker receives instructions like “Go there (insert locator ID, whether that be a location code, or sequence #) and pick that (insert product indicator and quantity). ”After completing this task with a product scan and quantity validation, the picker is then given the next set of similar instructions (the details and variations of how to complete this task are for another entry). Typically order header-type instructions will also be provided at beginning or end of these steps. But the problem that I see for many DSD customers is that they have limited visibility as to what product is going to come next. Forget about a user friendly way to see an overview of what is going to end up on this particular pallet. Without these two key things you end up trying to stack a stable pallet without knowing what real estate you are going to need to use next. So the user is left with dealing with one task at a time, leading to a lot of re-stacking halfway through the pick. Sorting of these tasks is your best option to limit the issue, but most techniques can be boiled down to one of two basic algorithms, each with benefits and limitations:

1. Efficient walk path.

a. PRO: You walk the most efficient path possible, therefore reduce the number of steps required to get from A to B.

b. CON: Without any consideration of individual SKU order quantity you may end up with a pallet appearing to mimic the Leaning Tower of Pisa

2. Pallet Stability

a. PRO: By considering the order quantity of individual SKU’s you get a very solid pallet, therefore reducing the probability of damaged goods.

b. CON: Given the unpredictable nature of DSD ordering patterns, your picker may need to invest in a new pair of walking shoes as they bounce back and forth from one corner of your warehouse to the other.

You may also be able to use slotting logic of your products based on overall volume to align products with your picking patterns. Or perhaps apply some secondary logic to limit bad combinations of products to reduce the issues with either option above, but you are likely still dealing with at least some of these problems (and possibly reducing the beneficial factors as well). I have helped our customers do similar steps in order to get them through these issues but my concerns with these limitations remained.

Lately when discussing their desires for paperless voice picking with customers I have been addressing a different method of implementing this…a mostly paperless solution with voice confirmation, rather than true “picking.” Instead of feeding out the pick commands over a headset the picker gets his pick ticket, with order lines and quantities sorted in one of the methods listed above in addition to his handheld gear. The picker can then identify which product to use as the pallet base. This is of great significance for DSD accounts because all products are not created equal when it comes to providing a stable base upon to build (or for that matter ability to withstand the weight of products stacked above). Look at the PRO/CON list of this offering compared with above:

PRO:

1. Pallet stability is maintained by selecting the most suitable base

2. Pallet stability is enhanced and re-stacking limited (or avoided) based on seeing subsequent pick lines/quantities

3. Walk path efficiency maintained, with the possible exception of that base product selection

CON:

1. Selecting of the first “base” product may contradict walk path efficiency

2. Paper pick ticket still printed rather than pure paper-free voice solution

In HighJump’s voice confirmation solution, the core validation pieces of voice picking are still maintained, i.e. the scan validation and verbal quantity confirmation. In addition, at the end of the pick the picker is prompted with any products missed from the pallet (the main concern of most operational contacts when hearing of this solution for first time).

I think this combination, while not truly paperless, provides the benefits of voice picking and ability allowing instant human interaction to build the best possible pallet.

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Comments for Paperless Voice Picking – Should This Move to Unicorn Status for DSD Operations?

Friday, April 30, 2010 by David Goomas:: I enjoyed the read, Derek. I offer two suggestions to remaining paperless. One suggestion: Working with the host company's Operations and Inventory Control departments, heavier ('base') product should be moved to the beginning of the aisle. That way when the order selector begins their assignment, heavier ('base') product is picked first. This removes the guess-work and flipping of pages by the order selector of trying to determine the best base. In my experience, I've seen 3 order selectors in the same picking section with 3 different ways of stacking the same pallet using the paper-based methodology. Another suggestion: Establish a Product Type Stacking Matrix within the WMS that identifies a product as, say, "base", "crushable", "topping" (to name a few). When the orders are sent to the WMS, the items are re-configured in the order of the Product Type Stacking Matrix sorted by descending quantity. You are absolutely correct in recommending to your customers to use slotting algorithms and addressing bad combinations of products. I would not address the second suggestion (product matrix) without addressing the first suggestion (product placement in warehouse). Executing the second suggestion leads to a lot of un-necessary travel, as you correctly indicated.in "Efficient Walk Path". Taken together, these two suggestions might maintain the paperless environment we all strive for. Thanks for your time.