If you have a picking face that’s spread over more than a few aisles, and contains a large range of SKUs, it makes sense to spread the stock around. Amazon does it and there’s no reason why you shouldn’t too.
Make sure your WMS allows you to control the ‘slotting’ logic that determines where SKUs are put in the picking face. At its most basic it should ensure that each of your most popular products are spread around so your most popular SKUs are all present in every aisle of the pick face. This will dramatically increase the proportion of picks that can be completed within a single aisle and reduce the distance your pickers have to walk.
8 – Training new team members is painful
Introducing new members of staff to your warehouse should be straightforward. In particular, once someone has been given a fifteen minute introduction to either process they should be up to speed very quickly, and it should not be possible for them to make mistakes.
If your warehouse processes are complicated by lots of workarounds, exceptions and funny little rules that have built up over time it can be almost impossible for new and temporary staff to get up to speed quickly and the whole process becomes more susceptible to errors whenever a new person starts. All the business rules surrounding each warehouse operation should be configured into the WMS processes that support them.