Mastering Split Case Picking with Automation

Split-case picking, often referred to as piece picking or each picking, is a fundamental warehousing process and critical to meet continuing e-commerce growth. As the demand for fast, accurate, and flexible order fulfillment grows, businesses are rethinking their strategies to optimize split case picking efficiency. This guide will explore what split case picking entails, its evolution, the benefits of automation, and how advanced solutions—like AutoStore—can streamline operations.

What Is Split-Case Picking?

Split-case picking involves selecting individual units from storage to fulfill orders instead of full pallet or case picking. This method is commonly used in e-commerce, retail, pharmaceuticals, and food and beverage industries, where orders often consist of mixed SKUs in smaller quantities.

Key terms related to split case picking include:

• Piece Picking: Selecting individual items.
• Each Picking: Another term for piece picking, emphasizing unit-level selection.
• Case Picking: Picking whole cases instead of individual items.

There are two main types of split case picking:

• Automated Picking: Systems like Goods-to-Person (GTP) technologies and robotics manage the picking process, reducing labor reliance and improving efficiency.
• Manual Picking: Workers physically retrieve items from storage locations.

The Evolution of Split Case Picking

Traditional Methods

Historically, split case picking relied heavily on manual labor. Workers traversed warehouses to pick items, often guided by paper lists or basic RF devices. While effective for smaller operations, this approach is labor-intensive, error-prone, and struggles to scale with demand.When juggling several plans and renewal schedules across multiple systems, annual upgrades and maintenance can be a nightmare. With one technology-neutral WES that communicates to all of your materials handling equipment, those headaches become a thing of the past. By centralizing and simplifying software management, WES reduces the cost and complexity of maintaining multiple systems.

Look for a WES that offers a configurable code base, for example, ensuring that upgrades and changes are managed efficiently without leaving your operations stranded on outdated, custom-built software.

Custom code solutions seem appealing initially but can become a significant liability over time. As software evolves annually or even more frequently, custom solutions quickly become obsolete and expensive to renew—a problem you can avoid with a configurable WES.

The E-commerce Boom

The rise of e-commerce has transformed the logistics landscape. Businesses now face unique fulfillment challenges, particularly in retail supply chains, such as managing high SKU counts and rapid delivery expectations. Addressing these complexities often require strategic solutions tailored to the unique demands of retail supply chains, including seasonal and omnichannel considerations. Learn more about adapting to today’s fulfillment challenges in retail and e-commerce supply chains. Consumers expect faster shipping and greater order accuracy, increasing the complexity of split case picking operations. Omnichannel fulfillment, high SKU counts, and seasonal demand fluctuations have pushed traditional methods to their limits.

The Role of Automation

Automation has emerged as the solution to modern challenges. Integrated systems often rely on warehouse software solutions like WCS, WES, and WMS to coordinate workflows and maximize efficiency. These tools play a vital role in ensuring smooth operations across picking and storage processes. Explore how these software solutions differ and their role in automation. Advanced robotic systems like AutoStore combine high-density storage with rapid retrieval capabilities, making split case picking faster, more accurate, and scalable. While no two operations are the same, these solutions can be customized to meet unique business needs.

Automated Solutions for Split Case Picking

Automation technologies are revolutionizing split case picking by minimizing manual labor, reducing errors, and boosting throughput. These advancements enable operations to adapt more effectively to high-demand scenarios, including peak seasons, where consistency and scalability are critical for success. AutoStore, a leading Goods-to-Person solution, offers tailored systems for diverse operational requirements:

AutoStore:

This high-density storage and retrieval system is ideal for operations with a large number of SKUs. AutoStore uses robots to retrieve bins containing the desired items, which are then delivered to picking stations for order assembly. This system optimizes space utilization and ensures rapid picking, making it a cornerstone for efficient split case operations.

AutoStore with Put Wall:

By integrating AutoStore with a put wall, businesses can enhance order consolidation processes. Picked items are directed to specific cubbies within the put wall, which organizes and sorts items into discrete orders. This setup is particularly effective for operations handling a high volume of multi-SKU orders, reducing errors and expediting the packing process.

AutoStore with Robotic Piece Picking:

Combining AutoStore’s storage capabilities with advanced robotic picking, this solution automates the selection of individual items directly from bins. The robotic piece picker ensures precision and speed, making it ideal for industries like e-commerce and pharmaceuticals where accuracy is critical. This integration reduces reliance on manual labor and increases throughput for high-demand environments.

These solutions enable businesses to adapt to fluctuating demand, improve space utilization, and streamline workflows.

Benefits of Split Case Picking Automation

Implementing automated split case picking systems delivers significant advantages:

• Enhances Flexibility: Automation supports diverse order profiles, from single-item picks to complex multi-SKU shipments.
• Reduces Labor Reliance: Automation minimizes the need for manual intervention, lowering labor costs and reducing worker fatigue.
• Improves Accuracy: Automated systems ensure precise picking, reducing errors and enhancing customer satisfaction.
• Increases Efficiency: By streamlining travel times and optimizing workflows, automation accelerates order fulfillment.
• Scalable Solutions: Modular systems can grow with your business, accommodating increased SKU counts and order volumes.

Designing the Right System for Your Needs

Choosing the best split case picking system requires a thorough assessment of your operations. Key considerations include:

• Order profiles and SKU characteristics
• Storage requirements and space constraints
• Desired throughput and accuracy levels
• Budget and return on investment (ROI)

KPI Solutions takes a consultative, technology-neutral approach to system design. Our experts work closely with you to analyze your needs and recommend the optimal combination of storage, picking, transport, and sortation technologies.

The Future of Split Case Picking

As e-commerce and customer expectations continue to evolve, so will the demands on split case picking systems. Technologies like AutoStore and robotic picking are leading the charge, offering businesses the tools they need to stay competitive in a fast-paced market. Ready to optimize your warehouse operations? Contact KPI Solutions to learn how our advanced split case picking solutions can transform your fulfillment processes.