The power of goods-to-person warehouse automation

But what exactly is goods-to-person (G2P) and how can it benefit your warehouse operations?

Let’s dive in and explore this game-changing approach to order picking.

Understanding goods-to-person fulfilment

Goods-to-person is a warehouse automation strategy that flips traditional picking methods on their head. Instead of workers traversing long aisles to locate and retrieve items — a method known as person-to-goods — G2P systems bring the inventory directly to stationary workers at ergonomic picking stations.

Here’s how it works: When an order comes in, automated systems retrieve the necessary items from storage and deliver them to a picking station. The worker then picks the items, confirms the order, and sends it off for packing and shipping. It’s a simple concept with profound implications for warehouse efficiency.

The key difference between G2P and person-to-goods systems lies in who — or what — does the moving. In traditional setups, workers might walk miles each day to fulfil orders. With G2P automation, that travel time is eliminated, potentially reducing picking time by up to 65%.

The technologies enabling goods-to-person warehouse automation

G2P systems rely on a variety of cutting-edge technologies to function effectively. Here are some of the key players:

1. Automated Storage and Retrieval Systems (AS/RS): These systems use cranes or shuttles to store and retrieve items from high-density storage areas. They’re the workhorses of many G2P setups, maximising vertical space and minimising retrieval times.
2. Robotic shuttles: These autonomous vehicles navigate storage aisles, fetching totes or bins and delivering them to picking stations. They’re nimble, efficient, and can work 24/7 without breaks.
3. Conveyor systems: While not as flashy as robots, conveyors play a crucial role in many G2P setups. They efficiently move items between storage areas and picking stations, creating a seamless flow of goods.
4. Pick-to-light and put-to-light systems: These systems use LED displays to guide workers, showing which items to pick or where to place them. They’re simple yet effective tools for reducing errors and increasing speed.
5. Voice-directed picking: This technology provides audio instructions to workers, allowing for hands-free operation. It can be particularly useful when integrated with other G2P technologies.
6. Vertical lift modules (VLMs): These automated storage units bring trays of items to an access window at an ergonomic height. They’re great for storing and retrieving small to medium-sized items in a compact footprint.
7. Automated guided vehicles (AGVs): These G2P robots navigate the warehouse floor autonomously, delivering larger items or pallets to picking stations or other areas as needed.

Spotlight on AutoStore: a goods-to-person game changer

Element Logic is the world’s first and largest distributor of AutoStore — a high-density AS/RS that exemplifies the power of G2P technology. Here’s why:

• AutoStore uses a grid of bins stacked vertically, with robots moving on top to retrieve and deliver bins to picking stations. This design maximises space utilisation, storing up to four times more inventory than traditional shelving.
• The system’s modular design allows for easy scalability and adaptation to various warehouse layouts. Whether you’re a small e-commerce startup or a large multinational, AutoStore can be tailored to fit your needs.
• Advanced algorithms optimise bin placement, ensuring frequently accessed items are stored for quickest retrieval. This ‘smart’ approach to storage continually improves efficiency over time.

Seven challenges to avoid in good-to-person implementation

While G2P systems offer tremendous benefits, implementing them successfully requires careful planning and execution. Here are some common pitfalls to avoid:

1. Inadequate system integration: Your G2P system needs to play nice with your existing warehouse management system (WMS) and other software. Poor integration can lead to data silos, inaccurate inventory counts, and delayed order processing.
2. Underestimating change management: Don’t forget the human element. Invest in comprehensive training and support for your team during the transition. Engage employees early in the process to foster buy-in and smooth adoption.
3. Insufficient analysis: Before implementing a G2P system, conduct a thorough analysis of your inventory and order profiles. This ensures you choose a solution that truly matches your specific needs.
4. Overlooking redundancy and backup plans: Even the most reliable systems can experience downtime. Have robust backup systems and contingency plans in place to maintain operations if technical issues arise.
5. Neglecting future growth: Choose a scalable and flexible G2P solution that can adapt to your evolving business needs. Consider modular systems like AutoStore that allow for easy expansion or reconfiguration as your business grows.
6. Prioritising speed over accuracy: While speed is crucial, it shouldn’t come at the expense of accuracy. Ensure your G2P system maintains a balance between swift operations and precise order fulfilment.
7. Ignoring ergonomics: Design picking stations with employee comfort and safety in mind. Proper ergonomics not only improves job satisfaction but also maintains productivity over long periods.

Five best practices for maximising goods-to-person benefits

To get the most out of your G2P system, consider these best practices:

1. Conduct comprehensive analysis: Before selecting a G2P system, thoroughly analyse your current operations and future needs. Consider factors like order profiles, SKU characteristics, storage density requirements, and throughput expectations.
2. Invest in robust training: Develop a structured training plan that covers both initial implementation and ongoing refresher courses. Well-trained employees will maximise the system’s potential and reduce downtime.
3. Regularly analyse performance data: Implement data-driven software that provides real-time visibility into key performance indicators. Use these insights to continuously optimise your G2P operations and maintain peak efficiency.
4. Implement preventive maintenance: Develop a comprehensive maintenance plan that includes daily checks, weekly inspections, and scheduled servicing. This proactive approach can prevent unexpected downtime and extend the lifespan of your equipment.
5. Ensure seamless integration: Work closely with your system provider to establish robust data interfaces. This means creating reliable connections between different software systems to ensure smooth information flow. Regularly test and update these integrations to maintain optimal performance across your entire warehouse ecosystem.

The future of warehouse automation is here

Goods-to-person systems represent a significant leap forward in warehouse automation, offering substantial improvements in efficiency, accuracy, and space utilisation. As e-commerce continues to grow and customer expectations for fast delivery rise, G2P systems are becoming increasingly crucial for businesses looking to stay competitive.

While implementing a G2P system requires careful planning and investment, the long-term benefits in terms of operational efficiency and scalability make it a worthwhile consideration for many warehouses. As technology continues to evolve, we can expect G2P systems to become even more sophisticated and integral to modern warehouse operations.

At Element Logic, we’re at the forefront of this warehouse revolution. Our cutting-edge warehouse automation solutions are tailored to meet your specific needs and drive your business forward.

Are you ready to transform your warehouse operations? Let’s talk about how we can help you harness the power of AutoStore. Contact us today for a consultation and take the first step towards a more efficient, accurate, and competitive warehouse operation.