Unlocking the Potential of Case and Item Picking Systems

No matter where warehouse leaders stand in their automation journey, one thing reigns supreme in their efforts to optimize their operations, increase storage capacity, and accelerate throughput: the picking process.

Whether it’s case picking for store fulfillment or item picking for B2B providers of important supplies, omnichannel retailers, or ecommerce stalwarts, picking processes are ground zero in most optimization efforts.

No other systems more directly address the most time-consuming task in warehouses – the 70% of time employees spend walking in facilities where manual picking processes remain. Fortunately, warehouse operators have numerous technology alternatives to choose from regardless of where they are in their automation journey. These solutions include:

• Goods-to-picker workstations: Highly intuitive and requiring only a few minutes of training, today’s workstations are more ergonomic and efficient than ever.
• Automated Storage and Retrieval Systems (AS/RS): Relied on in state-of-the-art facilities, AS/RS include sophisticated sequencing capabilities and offer dramatically greater storage capacity and exceptional throughput.
• Automated Case-handling Mobile Robots (ACRs) and climbing AS/RS: Using traditional warehouse racking, today’s ACRs and climbing variants offer fast implementation times and significant performance enhancements compared to manual picking. While they may not match the throughput of shuttle-based AS/RS, they provide a compelling alternative for operations seeking rapid and impactful upgrades.

The importance of data in the design and deployment of any of these systems cannot be overstated. Three factors leaders should keep in mind when getting on top of their data include:

1. Gather SKU and order data. To design an optimal automating picking system, you need a clear understanding of what items you’re handling and in what volumes;
2. Examine order details. For case picking systems, details like pallet height and the number of cases they can accommodate are important factors for system design; and
3. Ensure definitions are uniform. Details in data interpretation are important. For instance, does an order of 100 cases for one store count as one order or is it broken down into multiple sub-orders either by zones in the warehouse or departments in the store? And do you want to continue to interpret it that way in the future automated warehouse?

Other steps materials handling operations should take to ensure that their investments in picking technologies align with long-term growth goals and deliver the desired return-on-investment include:

• Create an integrated team: Leadership’s participation should begin early to ensure that new systems reflect the organization’s strategic plans. Equally important is including warehouse operators who have firsthand knowledge of current workflows. These team members can pinpoint bottlenecks, recurring workplace injuries, and inefficiencies that automation can directly address. Selecting these individuals for training on the operation, management, and maintenance of automated systems empowers them to play a key role facilitating the cultural change automation requires.
• Develop a compelling business case: The ROI of all automation can be summed up by determining if the benefits outweigh the costs associated with existing systems. Ideally, warehouses should create business cases that explore how different technology approaches, such as AS/RS and ACR systems, align with the organization’s goals and key metrics of success, both now and in the future. Opportunity costs, particularly around growth, should also be considered.
• Understand that automation is a journey: When evaluating picking technologies in RFPs, small performance differences, such as throughput metrics, often influence decisions. While these factors matter, long-term success depends on choosing technologies and partners that align with your organization’s needs and goals. Look for collaborators who understand your business, have a proven track record of supporting organizations through evolving challenges, and share your company’s values. Building a strong, long-term partnership ensures your automation efforts can adapt and thrive as your operations grow.

By combining these efforts with robust data management, thoughtful evaluation of available technologies, and a forward-thinking mindset, supply chain leaders can modernize their picking operations with confidence. With the right strategic approach, greater case picking and item picking performance is within reach.