Revolutionizing Manufacturing Warehouses – OPEX^® Perfect Pick^®

Discover how goods to person automation not only enhances throughput during busy periods but also reduces dependency on temporary staff, creating a stable, predictable operational model.

Manufacturing Warehouse Processes

The manufacturing industry serves as the backbone of global supply chains, transforming raw materials into finished goods for distribution across diverse markets. Manufacturers rely on robust warehousing and distribution centers to meet production demands and customer expectations, manage inventory, fulfill orders, and ensure on-time delivery. These operations typically involve intricate workflows, including the receipt, storage, picking, and shipment of goods. However, as supply chains evolve to meet the demands of e-commerce and just-in-time manufacturing, warehouses face increasing pressure to enhance efficiency, accuracy, and scalability while keeping costs low. Addressing these challenges often necessitates the adoption of advanced automation technologies that can streamline operations and maximize resource utilization.

Challenges Faced By Manual Operations In Manufacturing

Inefficiencies and constraints increasingly burden manual operations in manufacturing supply chains. Picking and storing processes require significant human labor, leading to bottlenecks during peak seasons or periods of high demand. Rising labor costs and workforce shortages exacerbate these challenges as warehouses struggle to maintain throughput without sacrificing quality. The physical demands of moving and lifting heavy boxes or picking large parts not only slow operations but also strain employees, increasing fatigue and injury risk. Excessive walking between pick locations extends fulfillment times, while workers often spend idle time waiting for orders to be released or determining which item to retrieve upon arrival. Static racking systems further limit vertical storage capacity, leading to inefficient layouts and wasted resources. Additionally, manual picking processes are prone to errors that disrupt downstream operations, delay order fulfillment, and erode customer satisfaction. These inefficiencies highlight the need for scalable, precise, and automated solutions to address modern manufacturing demands.

>2.6M

Items Picked by Perfect Pick

8:1

Space Savings

2.9

Years to Achieve ROI

How Perfect Pick Can Transform The Manufacturing Industry

Perfect Pick offers a transformative approach to manufacturing warehousing by leveraging advanced automation to optimize operations. At the heart of the system is the innovative iBOT® technology, which operates as a wireless, self-charging fleet of robotic vehicles capable of retrieving and delivering inventory totes directly to operators. This goods-to-person model eliminates unnecessary travel within the warehouse, significantly boosting picking speed and accuracy.

For example, consider a manufacturing warehouse with high SKU variability that faces fluctuating seasonal demand. Perfect Pick allows operators to initiate orders from a simple interface, such as the Cortex Equipment Control System (ECS), which integrates seamlessly with existing Warehouse Management Systems (WMS). The system prioritizes high-frequency items by slotting them closer to the operator’s station, reducing retrieval times. iBOTs autonomously navigate the system, selecting inventory totes based on order requirements and delivering them to ergonomic pick stations. Operators can process orders with minimal movement, using guided workflows like pick-to-light systems to streamline operations further.

This workflow not only enhances throughput during busy periods but also reduces dependency on temporary staff, creating a stable, predictable operational model. The flexibility to configure tote sizes and adapt the system’s scale ensures that Perfect Pick can grow alongside the business, accommodating new inventory needs or expansions without extensive retrofitting.

“THE PERFECT PICK SYSTEM IS PART OF THE WHOLE IDEA OF THIS CAMPUS – TO PROVIDE EFFICIENCY AND ENHANCED CUSTOMER SERVICE TO OUR CUSTOMERS.”

Bill Kullback

CFO, BioLegend

Benefits of Integrating Perfect Pick Into A Manufacturing Workflow

Integrating Perfect Pick into manufacturing workflows provides numerous benefits that align with operational and strategic goals. The system minimizes labor costs while maximizing productivity by automating storage and retrieval processes. Its high-density vertical storage optimizes warehouse layouts, enabling manufacturers to store more inventory in the same footprint. Enhanced picking accuracy reduces costly errors, which not only improves order fulfillment rates and customer satisfaction but also minimizes returns caused by incorrect picks.

Perfect Pick also contributes to long-term operational stability. Its self-contained iBOTs ensure continuous operation, even during individual unit downtime, avoiding the disruptions common with single-point-of-failure systems. Additionally, the system’s integration with existing WMS solutions ensures seamless data sharing and inventory tracking, allowing for real-time decision-making. By serving as a buffer storage location between the receiving dock and downstream manufacturing or assembly areas, Perfect Pick eliminates unnecessary touches, reducing labor costs and streamlining material flow. Some clients have cut handling steps from 15 to 5 by placing parts directly into the system upon receipt, eliminating the need for separate reserve storage locations. These efficiency gains contribute to a rapid return on investment, with an average ROI of just 2.9 years.

By implementing Perfect Pick, manufacturing warehouses gain a robust, scalable, and efficient solution that addresses the complexities of modern supply chain demands, paving the way for sustainable growth and operational excellence.

Want to Learn More?

Other Resources You Might Find Helpful