Order Fulfilment – Improved Omnichannel Order Accuracy

BEUMER Group Batch Sortation is designed to support a wide range of generic and project-specific scenarios across all types of warehouses. The batch management logic imports, as a precondition, SKU master data and order datasets from the Warehouse Management System (WMS). Using all this information, smart decisions are made to utilize the automation system to accomplish the shortest lead times for the managed orders.

This approach balances system capacity, generates picklists, retrieves items from automated storage and retrieval systems (AS/RS), sorts items, and monitors production progress for each batch. Throughout the process, status updates and anomalies are reported to operators, supervisors, and the WMS.

The batch-building strategy, tailored during the design phase of each project, ensures flexibility and efficiency.

Criteria for batch creation can include:

• Prioritizing same-day delivery orders to meet tight customer deadlines.
• Sorting fast-moving SKUs first to enhance operational throughput.
• Fulfilling single-item orders efficiently.
• Minimizing retrieval times by considering the distance from picking locations to induction points.
• Grouping batches based on picking locations to improve operations.
• Dynamically buffering prepicked items to ensure high-priority orders are fulfilled promptly.
• Organizing batches by item categories to enhance shop replenishment workflows.

Batches are managed in overlapping sequences to maximize system capacity. The intelligent sort logic ensures every inducted item is accurately registered and allocated to an open order within the current batch. As batch sortation progresses, the system can automatically start and complete batches as orders are fulfilled and new items are inducted. Supervisors retain the flexibility to adjust priorities, start or stop batches, and address operational needs in real time.

By improving workflow coordination, BEUMER Group Batch Sortation reduces manual intervention, enhances order accuracy, and accelerates fulfillment. Surplus items are efficiently allocated to compatible orders, while shortages are either flagged for re-picking, retrieved from storage, or noted as missing in the order manifest.

With its focus on balancing capacity and optimizing workflows, BEUMER Group Batch Sortation delivers greater efficiency, cost savings, and adaptability in dynamic operational environments.

BEUMER Group WCS oversees and automates key warehouse processes, from retrieving to shipping, ensuring efficient and accurate material flow across all connected systems. By aligning physical and logical integrations, the WCS keeps material tracking, inventory, and sub-systems synchronized while reducing manual handling. This approach minimizes errors and enhances overall operational efficiency.

Goods received are routed either to stock replenishment or directly to batch sortation if required. The WCS simplifies returns handling by enabling returned items to be added to storage or buffered for future batches, avoiding repetitive picking of fast-moving SKUs. This saves time and supports smoother operations, especially during high-demand periods.

For picked or retrieved items, operators receive clear instructions on the required number of SKU items to induct from a carton, ensuring both precision and consistency.

The sortation logic efficiently directs items to their appropriate destinations, such as batches, buffers, or stock, while managing multiple sortation processes simultaneously. For example, the WCS can handle sorting items to fulfill orders while preparing completed orders for shipping at the same time, keeping workflows uninterrupted even during peak activity.

Tailored sorting strategies, mostly focusing on order priority and order completion rate, enable accurate and efficient distribution of SKU items to orders. Sequencing items within an order — for instance, placing the largest item at the bottom of the carton — improves the packing process. Once sorting is complete, the WCS releases orders to the automated packing line, where cartons are verified for weight and volume, sealed, and labeled for shipping.