Picking/Sorting Solutions
Discover solutions designed to minimize errors and boost the efficiency of your picking and sorting processes.
Facing any of these challenges?
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With so many items, it's time-consuming to locate what we're looking for.
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Recruitment difficulties make it hard to expand our workforce.
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Having many similar items results in frequent mistakes during picking.
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Leveraging spot workers to offer simple and manageable tasks.
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With numerous steps in the picking process, training takes a significant amount of time.
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There are significant challenges to automating with robots.
What Can Be Improved
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01
Enhancing Picking and Sorting Accuracy
Pick to Light System and Projection Picking System drastically reduce human errors, enhancing the overall quality of shipments.
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02
Optimizing Picking and Sorting Efficiency
By leveraging logistics analysis, we design optimized picking and sorting workflows, combined with list-free digitalization. This approach significantly reduces task times and allows for efficient workforce allocation.
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03
Seamlessly adapting to diverse business models and packaging formats.
Leveraging our extensive lineup of picking solutions, we offer flexible adaptability to a wide variety of industries and packaging styles. From e-commerce to store shipments and bulk orders, we propose the most efficient picking and sorting methods tailored to meet your specific needs.
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04
Reducing Worker Burden
By utilizing picking carts and implementing systems such as DPS, DAS, and PPS®, workers no longer need to memorize item locations, enabling anyone to perform tasks effortlessly without overthinking. As a result, this approach reduces both the physical and mental strain on workers, creating a more comfortable and worker-friendly environment.
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05
Cost reduction
Eliminating the need for paper slips enables a shift to a paperless workflow while establishing a fully systematized warehouse operation. Improved efficiency and workforce reduction further cut labor costs and overall warehouse operation expenses.
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06
Ensuring scalability
With AIOI's hardware and highly scalable software, you can ensure system expandability to accommodate future increases in workload or changes in operations. Additionally, we offer flexible redesign and optimization tailored to your site, whether it's for human task support or a hybrid approach combining human efforts with robotics.
Proposal Examples
AIOI conducts logistics analysis on-site, identifies issues, and proposes optimal solutions to our customers.
Pharmaceutical industry Transforming Pharmaceutical Manufacturing: A Case Study on How Company A Overcame System Incompatibilities for Enhanced Efficiency
In the dynamic world of pharmaceutical manufacturing, staying ahead of operational demands is crucial. Company A, a leading pharmaceutical manufacturer, faced significant challenges as their existing third-party system no longer aligned with their current operational needs. Recognizing the urgent need for system upgrades and efficiency improvements, Company A turned to us for a transformative solution.
Challenge
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Increase in workload due to the rise in volume.
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A mix of large volumes for wholesalers and small volumes for medical institutions.
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Concerns about issues arising from system obsolescence.
Proposal
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Proposal based on logistics analysis: hearing and investigating your concerns.
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Simultaneous implementation of a shipping inspection system and processing of separate orders by five operators.
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Implementation of the latest systems based on extensive experience.
Implemented System
Effectiveness
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Time savings allow for peak season shipping without overtime or additional staffing!
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Labor productivity increased by 15%, and workers' walking distance reduced by 40%!
Case Study in the Publishing Industry Increased Productivity by Switching from List Picking to Pick to Light System
With around 1,600 items, picking was done manually by referring to paper order forms and sorting by bookstore shipping destinations. However, as the volume increased, picking errors and missing packages became more frequent, leading to the consideration of implementing Pick to Light System.
Challenge
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Manual list picking has led to frequent picking errors and missing packages.
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High dependency on veteran workers, and as the volume increases, adding more staff puts a burden on the site leaders.
Proposal
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When the number of picking items is high, the weight of the books increases. Therefore, using an automated conveyor system to transport them reduces the burden on workers.
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Install a signal tower (patlite) on each shelf to indicate the correct location.
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Implement a digital picking system capable of displaying up to 4 digits, with the indicator light color set to red only.
Key Points
- Easy Installation and Layout Adjustment of Light Modules.
- 2-core cable with no polarity prevents shorts due to incorrect installation.
Effectiveness
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Achieve a significant reduction in rework time caused by picking errors.
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The workload that previously took around 8 hours for a team of over 10 workers now takes only about 5 hours with a team of 10!
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The system allows anyone to perform the tasks, reducing the burden on site leaders and helping to control logistics costs, including labor expenses.
General merchandise industry A simple sorting system for A, B, and C items has been established, resulting in a 17% increase in efficiency and a reduction in labor requirements.
Proposing a system that simplifies the complex sorting of A, B, and C items, making it easy for anyone to use. This leads to a 17% increase in operational efficiency and a reduction in labor requirements.
Challenge
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The large number of items and varying shipping frequencies for each product have resulted in increased walking distances for workers, hindering productivity improvements.
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There was a need to realize a smart system that does not rely on veteran workers.
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There was an urgent need to achieve a reduction in the workforce.
Proposal
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Conduct logistics analysis based on product hit rates and divide storage areas into A, B, and C items.
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Using conveyors for operations shortens walking paths.
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In the A-item area, Light Modules are installed at each pick shelves.
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In the B-item and C-item areas, representative Light Modues are installed on the shelves to reduce costs.
This is the Picking System which strategically places high-frequency shipping items (A items) in flow racks around a central conveyor, while low-frequency shipping items (B and C items) are organized using medium-duty racks and conveyors. This layout ensures efficient workflow, reduces worker strain, and enhances the quality of operations on the floor.
Effectiveness
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Designed based on logistics analysis, our system shortens walking paths, achieving a 17% increase in operational efficiency.
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Our picking system is designed with simplicity in mind. Workers can easily follow the display instructions, making it user-friendly and accessible to anyone. This ensures a smooth and efficient picking process for all your operational needs.
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Achieve significant reductions in labor requirements.
