e-Warehouse - Order picking & Dispatch

🎯 Learning objectives

After successfully completing this course, you will be able to independently streamline the entire outbound logistics process, from initial order entry to physical handover to the carrier:

1. Order & data analysis (EQN method)

• Carry out quantitative order analyses: Analyse raw order data using the EQN method.
• Determine order profiles and warehouse zoning: Translate key figures into specific order profiles and warehouse zones, such as Single-Item, Multi-Item and Bulk/Pallet Picking.
• Reduce walking distances: Understand the crucial role of the order line as a driver of physical movement, and apply ABC analyses and slotting strategies to minimise non-value-added time.

2. Picking strategies, routing & WMS control

• Select & apply picking strategies: Weigh the advantages and disadvantages of Discrete Order Picking, Batch Picking, Group/Cluster Picking, Two-Step Picking, Zone Picking and advanced methods such as Swarm Picking using AMRs.
• Evaluate static versus dynamic approaches: Make informed choices between Picker-to-Goods (dynamic) and Goods-to-Picker (static/AS-RS), based on CAPEX, OPEX, lead time and flexibility.
• Use WMS control mechanisms: Understand how a WMS balances workloads through Wave Management, job generation and Task Interleaving.
• Apply routing patterns: Determine the optimal walking route (I-routing, U-routing or Z-routing) based on order density and aisle width.

3. Information flows & shop-floor technology

• Use communication technologies: Select suitable identification and communication tools, such as RF handheld scanners, Voice Picking, Pick/Put-to-Light, Smart Glasses/AR and RFID, based on accuracy, speed and ergonomics.
• Analyse the structure of picking documents: Understand how location codes and picking data should be structured to avoid search time and errors.

4. Consolidation, packaging & quality control

• Apply consolidation logic: Know how and when to combine partial orders based on order, customer, transport, time or product criteria, such as ADR or chilled goods.
• Organise consolidation techniques: Choose the right place and time for consolidation.
• Pack & identify goods: Select suitable secondary and tertiary packaging, understand box-sizing calculations, and know how to apply SSCC transport labels and customer-specific labels.
• Final checks & quality gates: Set up physical and administrative checkpoints for order completeness, weight checks, lot-number traceability and the generation of Advance Shipping Notices (ASN).

5. Outbound transport, loading & legislation

• Transport preparation & load plans: Prepare efficient load plans that account for delivery sequence, centre of gravity, load stability and maximum load utilisation.
• Load securing & legislation: Apply the basic rules of load securing, using lashing straps, anti-slip mats and shoring bars, and ensure that the maximum authorised mass (MTM) and maximum axle loads are not exceeded.
• Dock & yard management: Understand docking safety procedures and infrastructure, including Powerlock/Wheel-lok, dock levellers and dock shelters, and the management of dock occupancy.
• Manage document flows: Know the purpose and requirements of essential transport documents, including the CMR consignment note, packing lists, POD (Proof of Delivery) and ADR documents.

6. KPI monitoring & continuous improvement (Lean)

• Measure & manage performance: Calculate, analyse and report critical KPIs such as OTIF (On Time, In Full), Pick Accuracy, Order Accuracy, Perfect Order Rate and Dock-to-Ship Time to continually optimise the process through Kaizen/Lean.