What Is An Order Picker?

An order picker is a specialist machine, transforming how businesses handle materials, and we aim to help you better understand how it optimises operations, boosts safety, and streamlines the picking process. 

Continue reading to understand what an order picker is and its pivotal role in modern warehousing.

 

What are order pickers?

Order pickers are advanced industrial devices designed to streamline the retrieval process in storage and distribution settings. These pieces of equipment empower workers to access merchandise stored at considerable heights in safety and with ease.

In the logistics ecosystem, where timely order processing is paramount, order pickers are vital. They significantly reduce the time required for staff to collect items from elevated shelves. Their importance is especially pronounced in operations that demand rapid picking, such as online retail logistics and supply chains operating on just-in-time principles.

 

How do order pickers work?

Order pickers streamline the process of retrieving goods from various storage heights within warehouses, enhancing efficiency and safety. Here’s a step-by-step look at their operation:

 

• Activation: Operators commence the process by turning on the order picker, typically with a key-turn or push-button start procedure. A routine safety inspection is recommended at this stage, ensuring that the machine’s battery is adequately charged and all systems are functional.

 

• Manoeuvring to location: The operator then pilots the order picker to the specific warehouse aisle where the items are located. Designed for agility, these machines easily manoeuvre through the compact aisles prevalent in many storage environments. He is often guided by a specialist software system using barcodes and scanners.

 

• Elevating the platform: Upon reaching the targeted storage location, the lift is engaged, allowing the operator’s platform to ascend to the required shelf height. This elevation is designed to be both steady and accurate to facilitate the alignment with the desired inventory level.

 

• Item retrieval: From the elevated position, the operator manually collects the required items off the shelf. These items are generally placed into a storage container or onto a pallet situated on the picker.

 

• Engagement of safety protocols: During the picking process, various safety features are in effect. These may include protective barriers around the platform and attachment points for safety harnesses. There might also be proximity sensors that ensure the machine only operates when the operator is securely positioned.

 

• Descension and Item Transportation: With the items secured, the operator carefully lowers the platform back to a safe travel height and drives the order picker to the designated packing or dispatch zone within the facility.

 

• Operational Efficiency Enhancements: Modern order pickers may incorporate additional functionalities like integrated scanners for immediate inventory updates or navigational aids that direct the operator to subsequent pick locations.

 

Types of order pickers

Order pickers are essential assets in warehouse management, designed to meet a wide range of picking requirements and specialised needs. Here’s an overview of the different types available:

 

Entry-Level Pickers

Optimised for reachability within 2.5 metres of height, these pickers facilitate quick access to products at lower shelf levels, accelerating the pace of order fulfilment for tasks like e-commerce order processing.

 

Intermediate Pickers

 

These are engineered for securely retrieving goods at heights that peak around 6 metres. Featuring elevating control panels, they allow operators to navigate through various shelf levels efficiently without descending between picks.

 

Extended-Reach Pickers

Reaching the upper echelons of warehouse racks, some over 12 metres high, these pickers are instrumental in high-bay storage environments. Their safety measures are more robust, often including full enclosure platforms to protect operators at elevated heights.

 

Purpose-Built Pickers

Tailored to specific operational requirements, these pickers vary from those suited for chilled environments, preserving operator comfort and machine performance, to those customised for oversized items like furniture with more expansive platforms or specialised handling capabilities.

 

Rise-With Pickers

Also known as man-up pickers, they elevate the operator alongside the cargo, offering direct access to select and place items throughout the storage system.

 

Stay-Down Pickers

Opposite to the man-up variants, these pickers keep the operator grounded, with only the picking apparatus or forks moving upwards to fetch items, ideal for less elevated retrieval situations.

 

Oversized Item Pickers

They come into play for larger, bulkier items, providing the necessary platform size and lifting power to handle hefty products such as home furnishings.

 

Articulated Mast Vehicles

Turret trucks, while sometimes not classified strictly under order pickers, serve a comparable function in very narrow aisle warehouses. They are equipped with rotating forks, allowing them to pick from either side of the aisle without the need to reposition the vehicle, optimising space efficiency.

 

Why should you use an order picker?

Order pickers offer significant advantages for materials handling, contributing to a more productive and secure workplace. Here are three benefits that highlight their importance:

 

Safety advancements

Order pickers are engineered with built-in safety mechanisms that significantly lower the potential for work-related injuries. They mitigate the dangers associated with climbing ladders and manually handling materials at heights. Features such as secure guardrails, safety harness points, and operator presence sensors help to create a safer work environment. This focus on safety not only helps protect employees but can also result in fewer accidents, leading to lower insurance costs and less operational downtime.

 

Operational efficiency gains

These machines enable workers to access storage areas quickly and directly, streamlining the picking process. They navigate efficiently through the warehouse, lifting operators to the precise height necessary for item retrieval. This level of efficiency can be a critical factor in reducing order fulfilment times, which is essential for keeping pace with the demands of modern commerce. 

Furthermore, many order pickers come with advanced features like barcode scanners and system-guided picking, which simplify inventory control and route planning.

 

Ergonomic benefits

Order pickers are designed with the operator’s well-being in mind, promoting ergonomic work practices. They alleviate the need for employees to engage in potentially harmful actions such as overreaching or lifting heavy objects in awkward positions.

By allowing for a natural stance at the correct height relative to the stock, these machines help in minimising musculoskeletal strain. The ergonomic benefits they offer can lead to a happier workforce, less absenteeism, and a decrease in turnover rates due to work-related physical strain.

 

Conclusion

The order picker is an invaluable tool in the warehousing industry, driving efficiency, enhancing worker safety, and elevating productivity. As businesses strive to meet the ever-increasing pace of supply chain demands, the role of order pickers becomes more critical than ever, proving that smart technology is key to future-proofing logistics operations.