Modern warehouses face growing pressure to improve efficiency and speed up operations. The rise of e-commerce and same-day delivery demands has pushed warehouses to find better ways to store and retrieve items, such as a lift picker. Choosing the right equipment for order fulfillment can significantly affect how well a warehouse runs and how much it costs to operate.
This article compares two popular warehousing solutions: order pickers and vertical lift modules (VLMs). We’ll look at their features, benefits, and drawbacks to help you make an informed choice for your operation.
What are Order Pickers?
Order pickers come in various forms to meet different warehouse needs. Manual order pickers require workers to move through the warehouse to collect items physically. These machines can be as simple as hand trucks or as complex as powered lifting vehicles. Automated order pickers use technology to guide workers to the right locations or even move independently to pick items.
Advantages of Order Pickers
Order pickers have earned their place in many warehouses through years of reliable service. Workers can learn to use these machines quickly, making training new staff straightforward. The equipment can move between different areas of the warehouse with ease. Most warehouses can afford several order pickers because of their reasonable cost.
- Flexible movement between aisles and storage areas
- Simple controls that new workers can master quickly
- Lower upfront costs compared to automated systems
- Easy maintenance and repairs
- Ability to handle items of various sizes and weights
Limitations of Order Pickers
The traditional order picker system has several drawbacks that affect warehouse operations. Workers must spend long hours walking through aisles and climbing to reach items. The risk of accidents increases when workers need to work at height. These issues can lead to slower picking times and possible mistakes in order fulfillment.
- Higher risk of workplace injuries from falls and strain
- Inefficient use of vertical space in warehouses
- More chances for picking errors due to manual processes
- Limited productivity during peak periods
- Higher long-term labor costs
What Are Vertical Lift Modules (VLMs)?
Vertical lift modules represent a modern approach to warehouse storage and retrieval. These automated systems use vertical space efficiently by storing items in trays that move up and down within an enclosed unit. A computer controls the movement of trays, bringing requested items to an ergonomic pickup window. The system tracks inventory and manages storage locations automatically.
Advantages of VLMs
The implementation of VLMs can transform warehouse operations in several ways. These systems make better use of available space by storing items vertically, often reducing the storage footprint by 85%. Workers no longer need to walk through aisles or climb to reach items. The computer system helps prevent errors by guiding workers to pick the right items.
Challenges with VLMs
Installing VLMs requires careful planning and significant investment. The initial cost can be much higher than that of traditional order-picking systems. These machines need regular maintenance from skilled technicians. When technical problems occur, the system might stop working until repairs are completed.
Comparative Analysis
Cost Considerations
The financial impact of choosing between order pickers and VLMs extends beyond the purchase price. Order pickers cost less to buy but require more workers to operate. VLMs have higher upfront costs but can reduce labor expenses over time. Energy costs, maintenance, and training must all factor into the decision.
Efficiency and Productivity
Both systems offer different approaches to improving warehouse efficiency. Order pickers allow multiple workers to pick items simultaneously across various zones. VLMs can process orders faster within their area of operation. A VLM typically achieves picking rates two to three times faster than manual methods.
Flexibility and Scalability
Warehouses must adapt to changing business needs over time. Order pickers offer simple scalability by adding more units and workers as needed. VLMs require more planning for expansion but can grow vertically to maximize space usage. Both systems can handle changing product lines, though VLMs may need adjustment for very different item sizes.
Safety and Ergonomics
Worker safety and comfort play crucial roles in warehouse operations. VLMs bring items to workers at an ergonomic height, reducing physical strain. Order pickers require more physical movement and work at heights. The choice between systems can significantly impact worker satisfaction and injury rates.
Use Case Scenarios
Best Fit Scenarios for Order Pickers
Order pickers work best in certain warehouse situations. Small to medium-sized warehouses with varied product sizes often benefit from their flexibility. These systems suit operations with lower order volumes or those needing frequent changes in storage arrangements. Warehouses with budget constraints may find order pickers more practical.
Ideal Situations for VLMs
VLMs show their strength in specific environments. High-volume operations with consistent product sizes benefit most from these systems. Warehouses with limited floor space but high ceilings can maximize storage density. Operations requiring high accuracy and fast picking speeds often justify the investment in VLMs.
Conclusion
The choice between order pickers and VLMs depends on your specific warehouse needs. Order pickers offer flexibility and lower initial costs but require more labor and floor space. VLMs provide better space utilization and faster picking speeds but need a larger upfront investment.
When making this important decision, carefully consider your budget, space constraints, and operational requirements. The right choice will help your warehouse meet current demands while preparing for future growth.
Frequently Asked Questions
Q: Can we use order pickers and VLMs in the same warehouse?
A: Yes, many warehouses successfully combine both systems. You might use VLMs for small to medium-sized items with high turnover rates while using order pickers for bulky items or areas requiring more flexible access. This hybrid approach can help optimize both space and efficiency based on different product characteristics.
Q: How much maintenance downtime should we expect with VLMs?
A: Well-maintained VLMs typically require about 4-6 hours of planned maintenance per month. This includes system updates, mechanical checks, and cleaning. Emergency maintenance happens rarely, usually less than 1% of operating time. It’s recommended to schedule regular maintenance during off-peak hours.
Q: What’s a VLM system’s typical return on investment (ROI) period?
A: Most warehouses achieve ROI within 18-24 months after installing VLMs. The payback comes from reduced labor costs (40-60% savings), improved accuracy (up to 99.9%), and space savings (up to 85%). However, ROI can vary based on order volume, labor costs, and current inefficiencies.
