Comprehensive Warehouse Processes: From Receiving to Shipping
The essential warehouse processes, from receiving goods to final shipping. Each step, including put-away, picking, quality control, and packing, is crucial for smooth and efficient operations.
Receiving
Unloading goods from suppliers and verifying the delivery.
Example: Pallets of electronics, including smartphones and monitors, are unloaded at the receiving dock. The warehouse team checks these against the delivery invoice and, if necessary, tags each pallet with a barcode for tracking.
Solutions: Dock Scheduling Softwares, RFID (Radio-Frequency Identification) Readers, WMS (Warehouse Management System), Handheld Scanners, Conveyor Systems, Labelling Machine, etc…
Quality Control (QC)
Inspecting goods for defects or compliance with standards.
Example: After receiving the goods, the QC team (randomly) inspects pallets to ensure they meet quality and safety standards, separating any defective pallets, boxes or products for further review.
Solutions: QC Stations, AI-Powered Inspection tools, Barcode scanners, Handheld Tablets for Inspectors, Cameras with Machine Vision, etc…
Decanting
Breaking down large containers (pallets, boxes) into smaller units for easier handling and storage.
Example: Large boxes filled with multiple and mixed electronics (smartphones, earphones, chargers) are decanted into smaller bins or totes. This repackaging allows for easier access when fulfilling orders that require individual items. For example, a full pallet of smartphones might be divided into bins, with each bin containing a specific quantity of phones.
Solutions: Decanting Stations, WMS (Warehouse Management System), Barcode Scanners, Bins and Totes, GTP (Goods to person) Replenishment Station, etc…
Slotting
Strategically placing products in warehouse locations, with dynamic slotting adjusting placements based on real-time demand.
Example: Fast-moving items like new smartphones are stored close to the picking area, while slower-moving monitors are placed further back. During peak season, the system automatically shifts the location of high-demand items.
Solutions: WMS (Warehouse Management System), Demand Forecasting Tools, GTP (Goods to Person) Systems, Pick-to-Light Systems, Robotics, etc…
Put-Away
Moving goods to their designated storage locations.
Example: After slotting, the decanted bins containing smartphones are moved to specific racks in the high-turnover area. Larger items, like monitors, are stored in pallet locations deeper in the warehouse. The picking unit for smartphones may be a bin, while for monitors, it might be an entire pallet.
Solutions: WMS (Warehouse Management System), Barcode/RFID (Radio-Frequency Identification) Scanners, AMR (Autonomous Mobile Robots), AS/RS (Automated Storage and Retrieval Systems), Mobile Picking Carts, etc…
Storing
Keeping goods in designated storage locations until they are picked.
Example: The decanted bins of smartphones are stored in racks specifically optimized for small, high-demand items, while the larger monitors are kept on pallet racks. The storage system ensures the most efficient retrieval based on demand forecasts.
Solutions: WMS (Warehouse Management System), automated storage and retrieval systems (ASRS), mobile racking, vertical lift modules (VLM), robotics.
Picking
Retrieving goods to fulfill an order.
Example: An order is placed for five smartphones and one monitor. The warehouse system guides the worker to retrieve five smartphones from their bin location and one monitor from a pallet rack.
Solutions: Pick-to-light Systems, Voice-Picking Systems, Handheld Scanners, WMS (Warehouse Management System), Mobile Carts with Integrated Technology, AMR (Autonomous Mobile Robots), GTP (Goods to Person Systems), etc…
Consolidation
Grouping picked items into a single container for further processing or shipping.
Example: The picked smartphones and monitors are consolidated into a single bin for packing. If the order includes chargers from another section of the warehouse, they are rebinned with the rest of the items before final packing.
Solutions: WMS (Warehouse Management System), Sortation Conveyors, Automated Rebin Systems, Zone-Picking Systems, Put-Away Wall, etc…
Packing
Securing items in packaging for shipment.
Example: The consolidated items (smartphones, monitors, chargers) are securely packed into boxes with protective materials. Smaller items like smartphones are packed individually, while larger monitors are boxed separately.
Solutions: Automated Packing Machines, Barcode Labeling, WMS with packing modules, Cushioning Systems, etc…
Sorting
Organizing packed orders based on shipping criteria.
Example: After packing, the orders are sorted by delivery method—pallets of monitors for retailers and individual boxes of smartphones for consumers.
Solutions: WMS (Warehouse Management System), Sortation conveyors, Automated Sorters, RFID (Radio-Frequency Identification) Systems, etc…
Shipping
Dispatching orders to their final destination.
Example: The sorted boxes are loaded onto trucks. Large pallets of monitors are sent to retailers, while individual boxes of smartphones are shipped to online customers.
Solutions: WMS (Warehouse Management System), TMS (Transport Management Systems), Real-Time Tracking, Fleet Management System, etc…
Receiving Returns
Handling returned goods from customers.
Example: A customer returns a defective smartphone. The item is inspected, repackaged, and processed for either repair or restocking.
Solutions: WMS (Warehouse Management System) with return management modules, RFID (Radio-Frequency Identification), Automated Sortation Systems, etc…
Inventory Control
Monitoring and managing stock levels to ensure accuracy.
Example: The warehouse system tracks the exact quantity of tablets and accessories in real-time, preventing stockouts or overstock situations.
Solutions: RFID (Radio-Frequency Identification) tags, Cycle Counting Systems, WMS (Warehouse Management System), Barcode Scanners, ERP (Enterprise Resource Planning) Systems, etc…
Tracking and Reporting
Monitoring goods and generating reports on stock levels and warehouse performance.
Example: A dashboard displays real-time data on the number of laptops and their location in the warehouse, helping the team make informed inventory decisions.
Solutions: WMS (Warehouse Management System), RFID (Radio-Frequency Identification), Digital Twin, etc…