January 2026

In a traditional warehouse, productivity is limited by how fast a person can walk. Pickers often cover 8–12 km per shift, spending more time moving than actually picking. As order volumes grow, this “walking cost” quietly turns into lost throughput, labour inefficiency, and delayed dispatches. Goods-to-Person (GTP) picking flips this model on its head. Instead of people going to inventory, inventory comes to people — faster, smarter, and with far less human fatigue. What is Goods-to-Person Picking? Goods-to-Person is a warehouse picking strategy where automated systems deliver the required inventory directly to a fixed picking station. The picker stays in one place. The system handles movement, sequencing, and prioritisation. Some of the many common technologies used in GTP systems include: 1. Conveyors Used to transport totes, cartons, or trays from storage zones to picking or packing stations. Conveyors are ideal for high-volume, repetitive flows where speed and consistency matter. Best suited for: FMCG and retail warehouses Distribution centres with standard carton sizes 2. Autonomous Mobile Robots (AMRs) Robots retrieve shelves, bins, or totes and bring them to pick stations. Once picked, the robot returns the inventory to storage or moves to the next task. Best suited for: Dynamic warehouses with changing SKUs E-commerce and quick commerce operations Facilities needing scalability without major infrastructure changes 3. Carousels (Horizontal & Vertical) Carousels rotate inventory to present the right SKU at the right time. They significantly reduce search and travel time. Best suited for: Small to medium-sized items Spare parts, electronics, pharma, and apparel 4. Vertical Lift Modules (VLMs) VLMs store trays vertically and automatically retrieve them when required. They maximise vertical space while keeping high picking accuracy. Best suited for: Dense SKU environments Space-constrained warehouses High-value or sensitive inventory When Does a Warehouse Need Goods-to-Person? GTP is not a “nice-to-have” automation; it becomes essential when operational pressure crosses a certain point. 1. High Order Volumes As daily order lines increase, walking-based picking simply doesn’t scale. GTP systems allow warehouses to process significantly more orders per hour without proportionally increasing headcount. 2. Labour Shortages & Rising Costs Finding, training, and retaining skilled warehouse labour is increasingly difficult. GTP reduces dependence on highly skilled pickers and makes onboarding faster. Demand is volatile For products with fluctuating or unpredictable demand, order-based kitting prevents overproduction and aligns inventory directly with real orders. High SKU combinations When products can be bundled in many possible configurations, pre-kitting every combination becomes impractical. Order-based kitting offers greater flexibility. Customisation is required Customer-specific requirements, such as region-specific components or optional add-ons, are easier to manage when kits are assembled on demand. Advantages: Zero dead stock Since kits are not assembled until needed, there is no risk of unsold or outdated kit inventory. Better flexibility Warehouses can quickly adapt to changes in demand, product structure, or customer requirements, making this approach ideal for dynamic kitting solutions. Challenges: Without a robust WMS, order-based kitting can increase fulfillment time due to additional picking and assembly steps. This makes system support critical for maintaining service levels.   The Role of WMS in Kitting Operations A Warehouse Management System (WMS) is essential for executing both pre-kitting and order-based kitting efficiently within modern order fulfillment services. A WMS: Defines kit Bills of Materials (BOMs) Validates real-time component availability Guides order picking and assembly workflows Ensures inventory accuracy across both kits and components By integrating kitting logic into daily warehouse operations, WMS-powered order fulfillment solutions help reduce errors, improve speed, and deliver predictable outcomes—no matter which kitting strategy is used. Book a demo now! Read More Read SCM New.

Kitting is the process of combining multiple SKUs into a single saleable or deployable unit. In warehouse logistics, kitting plays a crucial role in the efficiency of order fulfilment services. The choice between pre-kitting and order-based kitting has a direct impact on inventory holding, order picking speed, and customer satisfaction. Choosing the right kitting approach depends on demand patterns, product complexity, and how mature your order fulfillment solutions are. Pre-Kitting Pre-kitting involves assembling kits in advance, before customer orders are received. These kits are stored as finished units and picked like a single SKU during fulfillment. It is used for a myriad of reasons, including when: Demand is predictable Pre-kitting works best when historical data shows stable, repeatable demand. In such cases, warehouses can confidently prepare kits in advance without the risk of frequent rework. Kits have a long shelf life Products that do not expire quickly or become outdated are ideal for pre-kitting. This reduces the risk of obsolescence while allowing inventory to be staged closer to dispatch. Assembly is time-consuming When assembling a kit requires multiple steps or quality checks, doing it ahead of time reduces pressure during peak order fulfillment windows. Advantages: Faster order processing Since kits are already assembled, fulfillment teams can skip the assembly step entirely. This significantly improves turnaround time for order fulfillment services, especially during high-volume periods. Lower order picking time Pre-kitted items reduce the number of individual SKUs that need to be picked. This simplifies order picking, minimises errors, and improves warehouse productivity. Challenges: Excess inventory If demand forecasts are inaccurate, pre-kitted stock can pile up, tying up working capital and warehouse space. Obsolescence if demand changes Changes in customer preferences, regulations, or product configurations can render pre-kitted inventory unusable, leading to write-offs. Order-Based Kitting Order-based kitting involves assembling kits only after a customer order is confirmed. Components are picked individually and assembled specifically for that order. It’s used in various situations and conditions, including: Demand is volatile For products with fluctuating or unpredictable demand, order-based kitting prevents overproduction and aligns inventory directly with real orders. High SKU combinations When products can be bundled in many possible configurations, pre-kitting every combination becomes impractical. Order-based kitting offers greater flexibility. Customisation is required Customer-specific requirements, such as region-specific components or optional add-ons, are easier to manage when kits are assembled on demand. Advantages: Zero dead stock Since kits are not assembled until needed, there is no risk of unsold or outdated kit inventory. Better flexibility Warehouses can quickly adapt to changes in demand, product structure, or customer requirements, making this approach ideal for dynamic kitting solutions. Challenges: Without a robust WMS, order-based kitting can increase fulfillment time due to additional picking and assembly steps. This makes system support critical for maintaining service levels. The Role of WMS in Kitting Operations A Warehouse Management System (WMS) is essential for executing both pre-kitting and order-based kitting efficiently within modern order fulfillment services. A WMS: Defines kit Bills of Materials (BOMs) Validates real-time component availability Guides order picking and assembly workflows Ensures inventory accuracy across both kits and components By integrating kitting logic into daily warehouse operations, WMS-powered order fulfillment solutions help reduce errors, improve speed, and deliver predictable outcomes—no matter which kitting strategy is used. Book a demo now! Read More Read SCM New.

Not all inventory deserves the same attention — yet most warehouses still manage every SKU as if it carries the same risk and value. This is one of the biggest hidden causes of working-capital loss, slow picking, and excess stock. ABC inventory analysis addresses this by clearly indicating where time, space, and money should be allocated. Rather than spreading effort evenly, ABC inventory management concentrates resources on the SKUs that actually drive revenue, service levels, and cash flow. What is ABC Inventory Analysis? ABC analysis of inventory is a method of ranking SKUs based on their business impact — usually a combination of sales value, usage frequency, and revenue contribution. It groups items into three classes: Class % of Items % of Inventory Value Nature A 10–20% 70–80% High value / fast moving B 20–30% 15–25% Medium importance C 50–60% 5–10% Low value/ slow moving This form of ABC classification in inventory management reveals a critical truth: a small number of SKUs control most of the warehouse’s financial and operational impact. A-items need precision, visibility, and tight control. C-items need cost-efficient storage and simple handling. B-items sit between the two Why ABC Analysis in Inventory Matters in Warehousing Without ABC inventory management, warehouses fall into inefficient patterns: High-value items get stored next to dead stock Fast movers are buried behind slow-moving SKUs Pickers walk longer distances for critical orders Stock counts take too long and miss the riskiest items When everything is treated equally, the warehouse becomes slow, expensive, and error-prone. With ABC classification in inventory management: A-items are placed close to dispatch and high-speed pick zones B-items get moderate control and accessible storage C-items move to high-density or bulk locations This reduces travel time, protects revenue-critical inventory, and prevents over-control of low-value stock. How WMS Enables ABC A modern WMS makes ABC inventory analysis automatic and continuous. Instead of manually assigning classes, the system: Analyzes order frequency, velocity, and sales value Applies ABC analysis of inventory at SKU and location level Reclassifies products as demand shifts Aligns storage layout, pick paths, and cycle-count rules accordingly For example: A fast-selling SKU that becomes a top revenue driver is promoted to A-class A slow-moving item drops to C-class and is moved to cheaper storage This allows ABC inventory management to stay aligned with real demand, turning the warehouse from a reactive operation into a data-driven system. Conclusion ABC inventory analysis brings structure to what is otherwise chaotic inventory management. By using ABC analysis of inventory, warehouses gain clear visibility into which SKUs deserve the most attention, space, and control. Instead of spreading effort evenly across thousands of items, ABC inventory management ensures that time, money, and resources are focused where they generate the highest return. With Pyrops WMS, this becomes a living, automated system. Pyrops WMS continuously applies ABC inventory analysis using real-time movement and sales data, dynamically reclassifying SKUs as demand changes. If you want to reduce picking time, gain tighter control over your inventory, and overall have smooth functioning operations, reach out to us now! Book a demo now! Read More Read SCM New.