![]() Complete batches move to sortation where orders are brought together in put walls before being sent for packing and dispatch. After all the items from a zone are picked, they are combined into whole batches in a process called staging. ![]() On release, batch items are divided for picking by zone so that the distance between items for a picker is minimized. Waves help coordinate shop floor activities by time - allowing other operations, such as stocking and cleaning, to take place efficiently. Batches group orders together and waves group batches together for periodic release. Large DHL warehouses use batch picking with wave release. Methods for picking order items in a warehouse (click to enlarge) Large warehouses use batch picking when collecting orders because individual order picking and cluster picking may involve an item picker spending time traveling several kilometers to fulfill an order. Warehouse operations and pick path optimization The project objectives were to develop a robust and smart system for testing different wave strategies and determine optimal warehouse throughput and resource utilization. Jigar Panot, a specialist at DHL Supply Chain’s Global Solutions Design Center, worked on a solution for a large-scale warehouse: To meet the goals, the organization chose to optimize its e-commerce operations, including the inbound activities of receive, stage, sort, and put away and the outbound activities of pick, sort, pack, stage, and dispatch. ProblemĭHL Supply Chain determined that two goals were essential to staying competitive in the growing e-commerce sector: meeting customer SLA (Service Level Agreements) and reducing operational costs. The project involved developing a smart and robust warehouse simulation tool for testing wave picking strategies.įor a warehouse with 500,000 SKU (stock-keeping units) and 249 staff, the warehouse optimization project produced strategies that reduced the time required for order completion by 8.2% and the number of required staff by 66.ĭHL Supply Chain is a division of Deutsche Post DHL Group with a global network and extensive logistics portfolio, including warehousing, transport, and value-added services. To reduce costs and remain competitive, DHL Supply Chain ran a warehouse operations optimization project. The global e-commerce sector has seen 320% growth in five years, and demand is increasing following the COVID-19 pandemic.
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