This is important, because case picking represents a high and growing level of cost for many distribution operations, yet it is about the only area for which not much true automation has existed.

Sure, there have been mechanized or partially automated systems, most commonly batch “pick to belt’ systems with downstream sortation. But full automation hasn’t really been in the cards until fairly recently.

You might say “split case” or “piece pick” processes haven’t been automated either, but that is not really true. While not for every company and certainly not for all products types, such automation systems as “A-Frames,” for example, provide full automation of piece picks that many industries (e.g., pharmaceuticals) have embraced for many years.

I could also argue that vertical or horizontal carousel systems offer a higher level of automation for piece picking (though again not for everyone) than we have really seen for case picking.

There really haven’t been equivalent solutions for case picking. Indeed, by far, the vast majority of case picking is done manually using pallet jacks or “order picker” trucks. At the same time, given changes in distribution, case picking volumes for most companies are going up versus full pallet quantities.

In addition, case picking is probably the single biggest source of picking errors, inventory errors and mis-shipments in the DC.

Naturally, an increase in case picking volumes and cost will cause companies to look for solutions to these operational pressures. Vendors are finally starting to deliver.

There are several interesting aspects to this:

• The emerging solutions use many different technologies. This is good generally, and means there are more options not just between vendors but between basic technology approaches, some of which will fit certain scenarios better than others. For example, some may be optimal if a company sticks with “layer picking”, but be not as good for less than layer picks (just as an example).

• Increases in case pick volumes, such as the case for many consumer goods manufacturers, means automating case picking becomes more easy to justify.

• The general trend towards fewer, larger DCs also makes it possible to better justify case picking automation.
  

Currently, SCDigest is working on a major research report on case picking automation. I know you will find it valuable. As part of that, we will be doing a brief survey of users on their case picking challenges. When that survey comes out, we would appreciate your taking a few minutes to answer just a few questions on the topic.

I am very interested and excited about this entire topic and research report. More from SCDigest and Distribution Digest soon.

Agree or disgree with Holste's perspective? What would you add? Let us know your thoughts for publication in the SCDigest newsletter Feedback section, and on the website. Upon request, comments will be posted with the respondent's name or company withheld.