Exploring Goods-to-Person (G2P) Picking Systems

Insights from Joe McGrath and Alex Swary

Goods-to-Person (G2P or GTP) picking systems are transforming how operations are conducted, in a world where the supply chain industry is constantly changing and evolving rapidly. These systems streamline the picking process by bringing items directly to the picker, which reduces travel time and boosts overall efficiency. Each G2P system is designed with unique features and capabilities to meet different operational needs.

What is a Goods-to-Person System?

Goods-to-Person (G2P) systems are automated solutions designed to bring inventory directly to the picking station, where human operators can quickly and efficiently process orders. Unlike traditional picking methods that require workers to travel through aisles to retrieve items, G2P systems utilize robotics, conveyor systems, and other technologies to deliver the necessary items to the picker. This approach minimizes the time and effort required to gather products, thereby enhancing overall productivity and accuracy.

Benefits of Implementing a G2P Solution

Implementing a G2P solution can offer numerous advantages for warehouse operations:

• Increased Efficiency: By reducing the distance workers need to travel, Goods-to-Person systems significantly increase picking speed and efficiency. This can lead to faster order fulfillment and improved throughput.

• Enhanced Accuracy: Automated systems help minimize human error by ensuring that the correct items are delivered to the picker. This can reduce the rate of picking mistakes and improve order accuracy.

• Optimized Space Utilization: G2P systems often make use of vertical space and compact storage solutions, which can help maximize the use of available warehouse space and improve storage density.

• Scalability and Flexibility: Many Goods-to-Person systems are modular and scalable, allowing businesses to easily expand their operations as needed. This flexibility makes it easier to adapt to changing inventory demands and business growth.

• Improved Worker Safety: By minimizing the need for manual lifting and extensive walking, G2P systems can help reduce the risk of workplace injuries and improve overall worker safety.

Overview of the Four Main Types of Goods-to-Person Solutions

• Grid-Based Systems: Grid-based systems use a grid of storage locations to house products, typically retrieved with a robotic solution carrying the rack or pallet to the pick station, and then returning to an available location. These solutions can be used to store and retrieve a variety of items, including parts, components, finished products, and raw materials. These solutions don’t require precision racking to be installed, and as a result, typically have short lead times compared to shuttles and other storage solutions.

• Shuttle-Based Systems: Shuttles work within a GTP system by retrieving the required tote that contains the item in need of being picked. The totes then get delivered to a worker. The inventory is then returned to storage and the next item is retrieved. Due to the rigid infrastructure of shuttles, they are capable of very high speeds and throughputs.  Shuttles generally excel in high throughput applications in excess of 5000 lines an hour and when the active SKU count is relatively low (less than 2000).

• Robotic G2P with Fixed Racks Storage: Some G2P systems require fixed racking to be designed and installed.  This racking structure is the basis for the active storage area where the robots retrieve products.  It allows for storage over 30’ high depending on the equipment and as a result is an incredibly structured use of warehouse space.  These solutions are typically advantageous in situations where the active SKU counts are more than 2000.

• Carousel Systems: Carousel-based solutions use a series of rotating shelves to store and retrieve items from totes. These solutions can be used to store and retrieve a variety of items, including parts, components, finished products, and raw materials. Carousels are well-suited for applications requiring multiple retrieval points close to them. They can also store and retrieve items in small batches, making them well-suited for order-picking applications.

Exploring Leading Goods-to-Person Systems

Exotec

Exotec is a high-performance Goods-to-Person solution known for its impressive reactivity and efficiency. The Exotec system is distinguished by its use of a single standardized robot configuration. This robot performs multiple functions in a single mission: presenting items to the picker, returning items to storage, and preparing for the next pick. The integration of these tasks within a single operation ensures that the system operates with remarkable speed and accuracy.

Pros

• 40′ Clear Height Utilization: Exotec is designed to leverage vertical space effectively, making it ideal for warehouses with substantial ceiling heights. This utilization of vertical space allows for high-density storage solutions that optimize the available warehouse area.
• Fast Reactivity: The system boasts the ability to retrieve any item from storage in approximately 2 minutes, irrespective of the SKU velocity. This rapid retrieval capability helps maintain high throughput and ensures quick order fulfillment, crucial for meeting customer expectations in fast-paced environments.
• Standardized Robots: By employing a single type of robot across the system, Exotec simplifies maintenance and support. This standardization reduces the complexity and cost associated with system upkeep, making it easier to manage and maintain.
• Flexible Adjustments: Exotec provides the flexibility to adjust pick station counts, presentation rates, and storage independently. This adaptability allows businesses to fine-tune the system to their specific needs, ensuring that it aligns perfectly with operational requirements and evolving demands.

Best Applications

Exotec is particularly effective for unit-picking operations, direct-to-consumer applications, and scenarios with stringent service level agreements (SLAs) involving a high number of SKUs. Its speed and adaptability make it a strong choice for businesses that require rapid and efficient order processing.

Hai Robotics

Hai Robotics offers a versatile G2P solution that caters to a wide range of product handling needs. The system’s robots are capable of managing various types of products, from cases and totes to pallets, all within a single integrated solution. This versatility makes Hai Robotics a flexible option for diverse inventory requirements.

Pros

• Versatile Handling: Hai Robotics systems are designed to handle a broad spectrum of product types, including direct case handling, totes, and pallets. This capability is particularly valuable for warehouses with diverse inventory, as it allows for the efficient management of different product formats within one system.
•  Flexible Fire Suppression: The system’s design incorporates less stringent fire suppression requirements compared to fixed rack solutions. This flexibility in fire suppression requirements can simplify warehouse design and reduce overall setup costs, providing greater design freedom.

Best Applications

Hai Robotics is well-suited for environments where products do not fit standard totes or where facilities have ceiling heights of up to 10 meters. Its adaptability makes it an excellent choice for warehouses with diverse product types and varying operational constraints.

Geek+ Shelf to Person

Geek+ offers a Goods-to-Person solution characterized by minimal fixed infrastructure and rapid deployment. This system is designed for businesses that need a quick-to-implement and scalable solution. The modular nature of Geek+ systems allows for easy expansion and adjustment, making it ideal for dynamic warehouse environments.

Pros

• No In-Rack Fire Suppression Required: The system eliminates the need for in-rack fire suppression, which simplifies both installation and ongoing maintenance. This feature reduces complexity and lowers operational costs.
• Fast Deployment: Geek+ systems are known for their quick deployment times. This rapid implementation allows businesses to start benefiting from automation sooner, enhancing operational efficiency and reducing time to market.
• Easy Expansion: The modular design of Geek+ systems makes them highly expandable. As businesses grow and their needs evolve, the system can be scaled up to accommodate increased inventory and changing operational requirements.
• Handles Various Product Sizes: The system supports a wide range of product dimensions, making it suitable for businesses with diverse inventory. This capability ensures that different product types can be managed effectively within the same system.

Best Applications

Geek+ is particularly effective in low-ceiling height buildings and for businesses requiring fast deployment. It is also a strong choice for companies with rapid growth projections and a high percentage of products that cannot be stored in traditional tote-based systems.

Autostore

Autostore is a highly efficient G2P solution known for its exceptional storage cube utilization. The system operates on a tote-based model and is recognized for its long-standing presence and proven performance in the industry. Its ability to deliver high storage efficiency without requiring excessively high ceilings makes it a versatile choice for various warehouse environments.

Pros

• Experience: Autostore is one of the most established Goods-to-Person platforms, with a track record of reliability and performance. Its long-standing presence in the industry attests to its effectiveness and robustness.
• Efficient Storage: The system is designed to maximize storage efficiency, even in warehouses with lower ceiling heights (under 25 to 30 feet). This capability allows for optimal use of available space, making it a practical choice for warehouses with height limitations.

Best Applications

Autostore is ideal for buildings with lower ceiling heights and order profiles that follow the 80-20 Pareto principle. It excels in scenarios requiring each-unit picking and direct-to-consumer (DTC) applications, where efficient storage and retrieval are crucial.

Opex

The Opex Perfect Pick system utilizes shuttle-based technology to transport items through a contained aisle. This system is known for its compact design and adaptability to various building constraints, making it a flexible solution for different warehouse environments.

Pros

• Condensed Solution: Opex Perfect Pick’s shuttle-based design allows it to fit into a wide range of building layouts and sizes. This flexibility makes it an attractive option for warehouses with space constraints or specific design requirements.

Best Applications

The Opex Perfect Pick system is particularly well-suited for small item unit picking, low-velocity SKUs, and spare parts fulfillment. Its design caters to environments where space optimization and efficient handling of small or infrequently picked items are important.

Interested in Implementing a Goods-to-Person Solution?

Goods-to-Person (G2P) systems are transforming warehouse operations by enhancing efficiency, accuracy, and space utilization. Whether it’s grid-based, shuttle-based, robotic with fixed racks, or carousel-based, each G2P solution offers unique advantages tailored to specific warehouse needs and operational challenges. The right Goods-to-Person system can significantly boost productivity and adaptability in a rapidly evolving supply chain landscape.

To find the ideal G2P solution for your warehouse, it’s crucial to consult with experts who can guide you through the selection process. At Hy-Tek Intralogistics, we help businesses like yours identify and implement the best G2P system to meet your goals and future growth. Schedule a discovery call with us today to see how we can assist in optimizing your warehouse operations and enhancing your supply chain efficiency. Reach out now to start your journey toward a more efficient and scalable warehouse solution.