How to reduce picking errors in warehouse and Superstores

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A coursework completed as part of the requirement for
COURSE NAME : Warehouse Management
COURSE CODE : GL006
LECTURER : Asst Prof. Siti Norida Binti Wahab
Entitled
ASSIGNMENT TITLE : SMARTTROLLEY APPLICATION REDUCEPICKINGERROR
IN WAREHOUSE,SUPERSTORESAND SHOPPINGCENTRES
Submitted on
DATE OF SUBMISSION : Friday, May 25, 2018
Produced by
STUDENT NAME & ID :
SL Name ID
1 Fahad Ahmed Naji 1001438942
2 Mohamad Nazmuzzaman Hye 1001748700
3 Mati Ur Rehman 1001748258
4 Pan xiuxiu 1001747770
Faculty of Business and Information Science (FoBIS)
Master in Science in Logistics Management (VYGL)
Portfolio # 2

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Table of Contents
1. Introduction...................................................................................................................................3
2. Automated Picking Vs. Manual Picking System.........................................................................3
3. Types of Picking Methods where Smart Trolley Can be used.....................................................3
4. Types of Error ...............................................................................................................................4
a. Types of Picking Errors in a Warehouse ...................................................................................................................................4
b. Types of Picking Errors in Super Stores and shopping center...............................................................................................5
5. How Smart Trolley works to reduce Picking Error.....................................................................5
6. Conclusion:...................................................................................................................................6
References .............................................................................................................................................7

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SMART TROLLEY APPLICATION REDUCE PICKING ERROR IN WAREHOUSE,
SUPERSTORES AND SHOPPING CENTRES
“Measured in time and money – order picking is, without doubt, the most costly activity in a
typical warehouse. It is also the activity that plays the biggest role in customer satisfaction with
the warehouse – and in the final analysis the entire Supply Chain.”
-------- **Professor René de Koster
1. Introduction
There are a lot of ways that Smart Trolley Application is helping us in warehouse, superstores and
shopping centres like, increased productivity, reduce labour costs, faster order fulfilment, Improve
order accuracy, better stock rotation, enhanced Customer service, Real-time operational visibility and
decision support system etc (Dematic Global Website, 2018). Productivity and Error rate is negatively
related. The Lower the error rate is the higher the productivity is. In the following section, we will
discuss how smart trolley system reduces picking error in the warehouse, superstores and shopping
center.
2. Automated Picking Vs. Manual Picking System
In today’s fast-paced environment, manufacturer, and distributors are pressured to efficiently fulfill
orders on time. In most cases, this leads to picking and staging orders prior to shipment, which
impacts the entire supply chain process. Following table shows how automated picking can improve
the entire supply chain process:
Difference Table : Automated Picking Vs. Mannual Picking
Automated Picking (Goods-to-Man) Manual Picking (Man-to-Goods)
Goods-to-Man is a modern method of order
fulfillment. The product is moved directly to the
operator, who can then pick what is needed to fulfill
orders. It allows for an increase in efficiency and
accuracy of the picking process. (Bastian Solutions,
2018)
The most common type of picking in practice is the
manual picking based on the principle of man-to-
goods. In picking systems like this the goods are
usually provided statically on shelves. The order
picker usually receives the process-relevant
information in the form of a list. (Günthner, 2009)
Automated picking -short travel times, high picking
rate, shorter lead times, improved service levels
(DÖLLINGER & LARSSON, 2016)
low picking performance compared to automated
picking solutions and the fact that humans make
mistakes. (Günthner, 2009)
Ideal concept for fast moving consumer goods and
where accuracy is critical (Wikipedia, 2018)
Ideal concept for slow-moving products in retail and
wholesale distribution centres. (Vanderlande, 2018)
3. Types of Picking Methods where Smart Trolley Can be used
methods are defined in terms of: (a) pickers per order - the number of pickers that work on a single
order at one time; (b) lines per pick - the number of orders a single item is picked for at one time; and
(c) periods per shift - the frequency of order scheduling during one shift. Order Picking Methods
Include ( Wheeler, 2014):
Zone Picking: Order pickers are assigned a specific and physically defined zone in the pick area. The
picker assigned to each zone is responsible for picking all of the SKUs located in the zone for each
order. In the event that an order requires SKUs that are located in multiple zones, the order is filled
after it passes through each zone. This is also referred to as the "pick and pass" methodology. In zone

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picking there is only one scheduling period per shift. This means there is a cut-off point for orders to
be queued into the order picking process and any order received after that cut-off point will get
fulfilled during the next shift. ( Wheeler, 2014)
Batch Picking: Batch picking is when one picker picks a group, or batch, of orders at the same time,
one SKU at a time. This is advantageous when there are multiple orders with the same SKU. When
that occurs, the order picker only needs to travel to the pick location for that specific SKU once, in
order to fill the multiple orders. The main advantage for choosing this method is reduced travel time,
which increases productivity. Batch picking is often used when the typical order profile has only a
few SKUs (under four) and the SKUs physical dimensions are relatively small. Just as in zone picking,
batch picking requires only one order scheduling window per picking shift. ( Wheeler, 2014)
Wave Picking: Wave picking is very similar to discrete picking in that one picker picks one order,
one SKU at a time. The main difference is the scheduling window. In discrete picking, there is not a
scheduling window whereas in wave picking there is. Orders may be scheduled to be picked at specific
times of the day, which is usually done to coordinate and maximize the picking and shipping
operations. ( Wheeler, 2014)
4. Types of Error
To error is human and order picking is not an exception. To conquer problems related to errors in
order picking, use of technologies is a common phenomenon nowadays. This section will discuss the
common types of Error made by pickers and shoppers. Also, this will justify why companies are
moving from conventional / Manual Picking system (Person-to-Goods) to Modern / Automated
Picking System (Goods to Person Picking system)
a. Types of Picking Errors in a Warehouse
The error rate of a conventional order picking system is on average about 0.26 %. This figure contains
different types of picking errors. A distinction is made between the following types of errors
(Günthner, 2009):
Miss Pick: The wrong item is picked in addition to the correct item. Also, it can be the wrong item is
picked instead of the correct item ( Wheeler, 2014).
Wrong Quantity (Short pick or Over pick): The wrong quantity of items is picked which can be
either too many or two few. ( Wheeler, 2014)
Omission Error: An order line item has been forgotten or an item is not picked at all. Sometimes the
omission error is referred to a special case of the short pick error with the quantity 0. (Günthner,
2009)
Condition Error: An incorrect action was carried out on the product. Condition errors are often
interpreted in different ways. Common examples are damaged products or improperly labelled
articles. (Günthner, 2009)

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b. Types of Picking Errors in Super Stores and shopping center
Beside many other functions, Smart Trolley ensures security measures by considering special cases
and giving its solutions (Ali & Riaz, 2015). These cases are mentioned below:
Omission: A customer forgets to keep a product into the trolley after scanning it. (Ali & Riaz, 2015)
Wrong Quantity (Short pick or Over pick): A customer scans one product but places multiple
products in the trolley. (Ali & Riaz, 2015)
Condition Error: A customer attempts to take away products in the trolley without scanning them
or A customer changes mind and removes the product from the trolley or A customer scans a cheaper
product and places the expensive product having the same weight. (Ali & Riaz, 2015)
5. How Smart Trolley works to reduce Picking Error
a. In Warehouse
In order to have an excellent warehouse performance, it is imperative to address the human
needs so that the errors can be minimised. Following table shows how smart trolley works in
warehouse to reduce various types of Picking Errors.
Table: How Smart Trolley Works in Warehouse to Reduce Picking Errors
Types of Error How Smart Trolley Works to Reduce Error
Miss Pick In a case where a picker may have picked and scan the wrong item
is in addition to the correct item or instead of the correct item in the
Smart Trolley, there is an important security measure to ensure the
third level of check. It is the placement of a small camera with a
barcode for image processing. So, when the product has scanned a
picture of the product is taken at the same time the picker’s trolley
ID and barcode picture is sent to the base station through sensor
mote by ZigBee packets having relevant information. (Ali & Riaz,
2015)
Wrong Quantity
(Short pick or Over pick)
The weight of products is an important factor to double check the
identity of product to protect against discrepancy or dishonest
activity. A load cell, which is basically a weight sensor, is located at
the bottom of the Smart Trolley. The output of the load cell helps in
decision making against abnormal activities. For example, if the
weight of the product measured by the load cell is not matching
with the actual weight of the product then it is referred as a case of
discrepancy at the base station (Ali & Riaz, 2015)
Omission Error When we can create a shipment for order in any WMS, that you can
easily export the associated pick list in the Smart Trolley
Application. When the Picker will scan the product, this will
automatically map with the list and also through scanning product
picture will be taken to confirm intended product from the Smart
Trolley’s tablet. (Ali & Riaz, 2015)
Condition Error

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b. In Superstores and shopping Centers
Where superstores and shopping Centre operations are very much dependent on manual works
and hence humans play critical roles and also Shoppers are human as well. To minimize the
human factor error Smart Trolley can works in the following way for verities of error:
Table: How Smart Trolley Works in Superstores and Shopping centre to Reduce Picking Errors
Types of Error How Smart Trolley Works to Reduce Error
A customer forgets to keep a product
into the trolley after scanning it.
The weight of products is an important factor to double check
the identity of product to protect against discrepancy or
dishonest activity. A load cell, which is basically a weight
sensor, is located at the bottom of the Smart Trolley. The output
of the load cell helps in decision making against abnormal
activities. For example, if the weight of the product measured by
the load cell is not matching with the actual weight of the
product then it is referred as a case of discrepancy at the base
station (Ali & Riaz, 2015)
A customer scans one product but
places multiple products in the trolley
A customer attempts to take away
products in the trolley without
scanning them
A customer changes mind and
removes the product from the trolley
If any customer after purchasing the product changes his mind
and wants to return the product, he just has to scan the product
again, product picture will be taken to confirm intended product
from the Smart Trolley’s tablet. (Ali & Riaz, 2015)
A customer scans a cheaper product
and places the expensive product
having the same weight
In a case where a customer may scan a cheaper product and
places an expensive product in the Smart Trolley, there is
another important security measure to ensure the third level of
check. It is the placement of a small camera with a barcode for
image processing. So, when the product has scanned a picture of
the product is taken at the same time the customer’s trolley ID
and barcode picture is sent to the base station through sensor
mote by ZigBee packets having relevant information. (Ali &
Riaz, 2015)
6. Conclusion:
For companies, it is necessary to design logistics processes in such a way that customer requirement
is met. This applies to both manufacturing companies and logistics service providers. The order
picking as a major logistics process has an important influence on customer satisfaction. In general,
the impact of picking errors depends on the time of their detection. Errors that are detected during the
picking by the order pickers themselves are not customer-relevant, but still, cause an expense in the
form of time and costs for their correction. This expense increases significantly when the error is
detected later in an internal control, e.g. in an outgoing goods inspection. Troubleshooting, in this case,
is more laborious because it could be necessary to re-stock a wrong item and to generate a new order
to pick the right items. If defective consignments leave the warehouse and errors are discovered by the
customer, this results in a complaint and the related costs of complaint handling in the short term. In
the long term, this can also lead to the loss of image and customers. Especially when production
systems are supplied just-in-time, costs for subsequent delivery via express or damages for a
production line stop can explode. Undetected errors can have serious consequences. Assuming that a
wrong component is installed in a vehicle or a facility, machines can be damaged or even human lives
or health can be endangered. Use of Smart Trolley Application can reduce the consequences of Picking
error in any logistics system.

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References
Wheeler, C. (2014, June 30). Retrieved from NewCastleSystems :
https://www.newcastlesys.com/blog/bid/349401/picking-error-problems-suggestions-and-
solutions
Ali, S., & Riaz, M. (2015). Technology Evaluation and Commercialization_Report_SMART
TROLLEY . Researchgate .
Bastian Solutions. (2018). Retrieved from Solutions:
https://www.bastiansolutions.com/solutions/technology/goods-to-person
Dematic Global Website. (2018). Retrieved from Supplychain Solutions:
http://www.dematic.com/en/supply-chain-solutions/by-supply-chain-function/case-picking/
DÖLLINGER , A., & LARSSON, T. (2016). Automated Storage and Retrieval within Contract
Logistics . Gothenburg, Sweden : CHALMERS UNIVERSITY OF TECHNOLOGY .
Günthner, W. A. (2009). Active Prevention of Picking Errors by Employeeing Pick by vision.
Vanderlande. (2018). Retrieved from Warehousing:
https://www.vanderlande.com/warehousing/innovative-systems/order-fulfilment/goods-to-
man
Wikipedia. (2018). Retrieved from Automated storage and retrieval system:
https://en.wikipedia.org/wiki/Automated_storage_and_retrieval_system
** Prof. René de Koster
Professor of Logistics and Operations Management
Department of Technology and Operations Management
Rotterdam School of Management (RSM)
Erasmus University Rotterdam