Stock Picking In Distribution Centres And Warehouses Training

Objectives:
• Understand the role of stock picking in distribution centres and warehouses
• Identify different types of stock and storage systems
• Explain the importance of accuracy and efficiency in stock picking
• Recognize safety and ergonomic considerations
• Describe the impact of stock picking on customer satisfaction

Topics:
• Overview of warehouse operations and stock picking
• Types of inventory: raw materials, WIP, finished goods
• Storage systems: pallet racking, shelving, bin locations
• Key performance indicators: accuracy, productivity, cycle time
• Safety fundamentals: manual handling, PPE, housekeeping
• Ergonomics in picking: reducing strain and injury

Objectives:
• Compare different order picking methods (discrete, batch, zone, wave)
• Select appropriate equipment for various picking scenarios
• Understand the use of pick carts, pallet jacks, and forklifts
• Apply principles of pick path optimization
• Implement labeling and barcode scanning basics

Topics:
• Discrete vs. batch picking
• Zone picking and wave picking
• Pick carts, pallet jacks, and walkie riders
• Forklift types and safe operation
• Pick path planning: reducing travel time
• Barcode scanning and label placement

Objectives:
• Describe the role of WMS in directing picking activities
• Use RF scanners and voice-directed picking systems
• Understand pick-to-light and put-to-light systems
• Apply automated storage and retrieval systems (AS/RS)
• Evaluate the benefits of technology for accuracy and speed

Topics:
• Warehouse Management System (WMS) functions
• RF scanning: navigation and confirmation
• Voice-directed picking: headsets and commands
• Pick-to-light and put-to-light technologies
• Automated storage and retrieval systems (AS/RS)
• Pros and cons of technology implementation

Objectives:
• Implement ABC analysis to prioritize SKU placement
• Apply slotting optimization to reduce travel time
• Use wave planning and order batching effectively
• Understand cross-docking and its impact on picking
• Calculate pick rates and set performance benchmarks

Topics:
• ABC classification and fast-movers placement
• Slotting optimization: golden zone, cube utilization
• Wave planning: grouping orders by priority
• Order batching: consolidating similar items
• Cross-docking basics
• Measuring pick rates: units per hour, lines per hour

Objectives:
• Implement pick verification methods (scanning, weighing)
• Conduct cycle counts and reconcile discrepancies
• Apply quality checks during and after picking
• Understand the impact of errors on customer satisfaction
• Develop error reduction strategies

Topics:
• Pick verification: barcode scanning, weight checks
• Cycle counting: daily, weekly, periodic
• Quality control checkpoints
• Error types: wrong item, quantity, damage
• Root cause analysis for picking errors
• Corrective actions and continuous improvement

Objectives:
• Identify common safety hazards in picking areas
• Apply proper lifting techniques and ergonomic practices
• Comply with OHS Act and relevant regulations
• Use personal protective equipment correctly
• Respond to emergencies and incidents

Topics:
• Hazard identification: slips, trips, falls, collisions
• Manual handling: safe lifting, carrying, lowering
• Ergonomic tools: adjustable workstations, anti-fatigue mats
• OHS Act requirements for warehouses
• PPE: high-vis vests, safety boots, gloves
• Emergency procedures: fire, spill, injury

Objectives:
• Understand the relationship between picking and replenishment
• Apply replenishment triggers and methods
• Manage stock rotation (FIFO, FEFO)
• Handle returns and reverse logistics
• Use inventory reports to optimize stock levels

Topics:
• Replenishment triggers: min/max, Kanban
• Replenishment methods: case, pallet, broken case
• Stock rotation: FIFO vs. FEFO
• Returns processing: inspection, restock, disposal
• Inventory accuracy reports
• Stock level optimization: safety stock, reorder points

Objectives:
• Define key performance indicators for picking operations
• Analyze pick data to identify bottlenecks
• Apply Lean principles to reduce waste
• Implement 5S in the picking area
• Develop a continuous improvement plan

Topics:
• KPIs: pick accuracy, productivity, cycle time, cost per pick
• Data analysis: pick density, travel time, error rates
• Lean principles: value stream mapping, waste elimination
• 5S: Sort, Set in Order, Shine, Standardize, Sustain
• Kaizen events for picking improvements
• Creating a culture of continuous improvement

Objectives:
• Integrate all concepts into a cohesive picking operation
• Complete a simulated picking exercise with technology
• Assess understanding through practical and written tests
• Develop an action plan for workplace implementation
• Review unit standard requirements and portfolio evidence

Topics:
• Simulated picking exercise: order processing to dispatch
• Practical assessment: pick accuracy, safety, efficiency
• Written test on key concepts
• Portfolio of evidence: logbook, checklists, reports
• Action plan for workplace implementation
• Course review and Q&A