Picking Speed vs Picking Accuracy
"Pick Rate" (Items Per Hour) is the vanity metric of warehousing. "I picked 300 items an hour!" "Great. But you sent Mrs. Jones a cucumber instead of a courgette."
The Cost of Error
A picking error costs:
- The Refund: £2.00.
- The Support Call: £5.00 (labour).
- The Redelivery: £6.00 (driver time + fuel).
- The Churn: LTV of £500 lost.
Total Cost of a "fast" mistake: £500+.
Slow Down to Speed Up
Implement "Scan Verification." The picker must scan the barcode. Not just look at the item. This slows them down by 2 seconds. It saves you thousands of pounds.
The "Perfect Order" Metric
Stop bonuses based on Speed. Start bonuses based on "Perfect Orders." Speed without accuracy is just efficient chaos.
Frequently Asked Questions
What is a good Pick Rate?
In grocery, 150-200 units per hour is standard for manual picking. 600+ for automated/zone picking. But it varies wildly by warehouse layout.
How do barcodes improve accuracy?
Visual checks fail because packaging looks similar (e.g., Raspberry vs Strawberry Yoghurt). Barcodes (EANs) are unique. The scanner doesn't get tired or distracted.
What is "Six Sigma" in warehousing?
A data-driven methodology to eliminate defects. In picking, aiming for 99.99966% accuracy (3.4 defects per million opportunities).