As order volumes increase, keeping warehouse operations organized becomes more demanding. Workers must sort items for different customers without mixing products or slowing down dispatch, and even small sorting mistakes can lead to delays, incorrect shipments, and additional costs. These challenges make it worth exploring better ways to manage the movement of picked items before they leave the warehouse.
One approach is a put-wall system, which uses designated compartments to separate products according to their destination orders. By bringing structure to the sorting and consolidation stages, this system can help warehouse teams handle multiple orders with greater accuracy and less manual confusion. Understanding its features and practical applications can help businesses determine whether a put-wall system fits their fulfillment needs.
Key Takeaways
Put-wall systems streamline picking and packing processes by providing a dedicated area for unsorted inventory, leading to increased productivity and faster order fulfillment.
Put-wall systems find applications across various warehouses and distribution centers, particularly benefiting e-commerce operations dealing with SKU proliferation and high throughput requirements.
HashMicro Warehouse Management Software can automate inventory management, simplify order processing, and improve overall operational efficiency.
What Are Put Walls?
Put walls play a crucial role in order consolidation and sorting processes, streamlining the picking and packing process in warehouses. After batch picking runs, put walls provide a dedicated storage system that eliminates the need for sorting during the picking process, reducing the time it takes to complete a picking job. With put walls, pickers can unload unsorted inventory into designated locations, enabling a more efficient follow-up sorting process.
Put walls come in various styles and complexities to suit different warehouse layouts and operations. Their primary function is to facilitate order consolidation and provide an organized storage system for unsorted inventory. By separating the picking and sorting processes, put walls enhance the efficiency of warehouse operations and enable streamlined picking and packing processes.
Also Read: Getting to Know Consolidation Warehouse
Differences Between Put-to-Wall and Put-to-Light
The two terms are often confused because both speed up order fulfilment and sorting, but each solves a different part of the job.
| Aspect | Put-to-Wall | Put-to-Light |
|---|---|---|
| Core idea | A wall of compartments, each assigned to one customer order | An electronic display showing the correct location and quantity for each item |
| Main purpose | Sorts multiple orders at one station after batch picking | Guides operators so each unit lands in the right place faster |
| Operator action | Places picked items into the slot for their order | Follows the lit display to the correct slot and quantity |
| Relationship | Can run on its own | Can be added to a put wall as an assistive layer |
Put-to-wall optimises how goods are sorted before packing, while put-to-light speeds up the placement task itself. In both cases, a warehouse management system supplies the instructions that keep operators accurate.
How Do Put Walls Work?
Put walls play a crucial role in optimizing warehouse efficiency and streamlining order fulfillment processes. But how exactly do put walls work? Let’s take a closer look.
When batch pickers collect inventory for orders, they unload the unsorted items into a designated area known as the put wall. This area acts as a hub for order receipt and shipment preparation.
Once the items are placed in the put wall, they can be sorted based on their specific destination. This sorting process involves transferring the inventory into the appropriate sorting bins or containers.
Advanced put-wall systems leverage assistive technologies such as put-to-light systems and robotics to improve efficiency and accuracy.
Put-to-light systems use visual identifiers, much like pick-to-light systems, to guide pickers to the correct location within the put wall. This technology helps reduce errors and speeds up the sorting process, ensuring items are placed in the correct bins.
Robotics and automation technologies are also integrated into some put-wall systems. These technologies automate the scanning, identification, and consolidation of orders, further enhancing efficiency and accuracy.
One innovative approach to put walls is the U-shape approach. This flexible and mobile put-wall system is designed to handle varying order volumes and optimize space utilization within the warehouse.
Efficiency gains achieved through the utilization of put walls and these assistive technologies contribute to overall warehouse efficiency and improved order fulfillment processes.
Order Fulfilment Process With the Put-to-Wall System
The exact sequence varies by facility, but a typical put-wall order flow runs through five stages.
- Order receipt. The fulfilment software selects the products needed and sends picking instructions to operators.
- Product picking. Operators walk the warehouse with a cart, collecting items for several orders at once.
- Sorting at the put wall. Pickers place each item in the slot assigned to its order, so one slot holds one order.
- Order verification. Operators check that every order is complete and correct, usually with help from a WMS.
- Packing and labelling. Verified items leave the put wall for the packing area, where they are packed and labelled for distribution.
In most put-wall setups, a warehouse management system that coordinates order allocation tells each operator which slot belongs to which order, which keeps sorting accurate at high volumes.
Key Benefits of Put-Wall Systems
Put-wall systems offer several key benefits to warehouse operations that can significantly enhance picking and packing efficiency, improve order fulfillment accuracy, and provide scalability and flexibility in handling different order volumes. Let’s explore these benefits in detail:
Increased picking and packing efficiency
Put walls streamline the picking and sorting process by providing a dedicated area for unloading unsorted inventory. This optimized workflow allows employees to focus on one aspect of the order fulfillment process at a time, leading to improved overall efficiency. With a well-implemented put-wall system, your warehouse can achieve higher productivity levels and expedite outbound shipments for faster delivery.
Improved order fulfillment accuracy
By centralizing the sorting process, put walls minimize the chances of errors during order fulfillment. With designated areas for specific SKU types, pickers can easily sort items into the appropriate bins, reducing the risk of misplacement or misreading of labels. This increased accuracy translates to enhanced customer satisfaction, fewer returns, and reduced operational costs.
Scalability and flexibility
Put-wall systems are highly adaptable to changing order volumes and warehouse requirements. Whether your warehouse deals with seasonal fluctuations or experiences growth in order volume, put walls can easily scale to accommodate the demand. Their modular design allows for easy reconfiguration and expansion, ensuring your warehousing operations remain efficient and flexible in meeting evolving customer needs.
Businesses planning to expand their put wall can also compare the best warehouse management software options first.
Optimized warehousing operations
Implementing put walls optimizes labor efficiency and enhances overall operational efficiency. By separating the picking and sorting processes, employees can specialize in their respective tasks, minimizing time wasted on transitioning between different activities. This division of labor also simplifies training and onboarding processes, making it easier for new hires to become fully productive in their roles. With put-wall systems, your warehouse can achieve greater productivity and accuracy while reducing operational complexities.
Applications of Put-Wall Systems
Put-wall systems are highly versatile and find applications in various types of warehouses and distribution centers, including those involved in e-commerce fulfillment operations. With the ability to be used in both manual and automated picking systems, these systems offer adaptability and efficiency across different environments.
E-commerce operations, in particular, greatly benefit from the implementation of put walls. They enable the consolidation and sorting of small average orders, facilitating streamlined order fulfillment processes. Put-wall systems are ideal for warehouses dealing with SKU proliferation, varied order profiles, and high throughput/velocity requirements, ensuring efficient management of inventory and order flow.
Whether in warehouses or distribution centers, put walls play a crucial role in optimizing operations. They enhance productivity and accuracy by enabling dedicated areas for unloading and sorting inventory, mitigating errors and improving overall efficiency.
By leveraging put-wall systems, businesses can achieve seamless and effective order fulfillment, enhance customer satisfaction through timely deliveries, and efficiently manage warehouse operations in Singapore’s dynamic market.
Conclusion
Put-wall systems represent an important solution for modern warehouses and distribution centers in Singapore, where efficiency and accuracy are paramount. By implementing this system, businesses can optimize their packaging processes, improve order fulfillment operations, and adapt to evolving customer demands. With the ability to scale and accommodate various order volumes, especially with integrated software, put walls are a versatile and effective solution for simplifying warehouse operations.
Warehouse Management Software like HashMicro is designed to increase warehouse efficiency by seamlessly integrating with put-wall systems. With HashMicro warehouse management software, you can automate inventory management, simplify order processing, and improve overall operational efficiency. get a free demo now with HashMicro!
Frequently Asked Questions
Batch picking is a method where an operator collects items for several orders in a single trip through the warehouse, instead of picking one order at a time. The picked items are then sorted by order afterwards, which is where a put wall comes in.
The cost depends on the number of slots, whether the put wall is manual or automated, any put-to-light or robotic add-ons, software integration, and installation. A simple manual layout usually costs less than a light-guided or automated setup, so suppliers typically price it by quotation.
It can be, provided the warehouse handles enough small, multi-item orders to justify a dedicated sorting area. A put wall can be expanded as order volumes grow, but a warehouse with few orders may find picking one order at a time simpler.
A manual put wall can run on paper lists or labels, but accuracy and speed drop as order volumes rise. Most put walls are paired with a warehouse management system that tells operators which slot belongs to each order and checks that every order is complete.
