Goods-to-person (G2P) systems are a revolutionary solution in warehouse optimization. These systems streamline operations by delivering items directly to warehouse staff, reducing travel time and increasing productivity.

Below, we discuss the four main types of G2P systems and the benefits they bring to warehouses. 

Carousel Systems

Carousel systems use rotating shelves and bins to bring products to a fixed packing station. This system is ideal for operations that handle a high volume of small to medium-sized items. Carousel systems are most commonly found in industries where quick access to a variety of stock and space optimization is necessary. 

Carousel systems can either be horizontal or vertical. Horizontal carousels have a series of bins attached to an oval track rotating horizontally, while vertical carousels rotate bins up and down along a vertical track. Software controls the system and directs the carousel to rotate to present the correct item to the workstation operator. In particular, vertical carousels are excellent at optimizing vertical space in tight environments. 

The biggest pro of this goods-to-person system is that items are delivered directly to the picking station, reducing walking and search time for pickers. Due to computer-controlled operations, human errors are minimized. However, scalability with this system can be challenging, as it requires full installation of additional systems. 

Vertical and Horizontal Lift Systems

Vertical and horizontal lift systems work similarly to carousel systems but are designed differently. These systems can still store and retrieve items with minimal footprint, which is ideal for warehouses with diverse products needing high-density storage. Lift systems are made of automated shelves that move vertically or horizontally to deliver items to a workstation, rather than rotating like a carousel. 

Vertical Lift Modules (VLMs) have two columns of trays with an extractor in the center that retrieves stored items and brings them to the access opening. Horizontal lift systems move the trays on a horizontal axis and are best used in warehouses with limited ceiling height. These systems optimize storage to reduce space utilization and can store a variety of object shapes and sizes. They are also useful in environments needing controlled access to sensitive or high-value items. 

Since items are quickly retrieved and delivered to the picking station with these lift systems, order fulfillment speed can be maximized, improving customer satisfaction. These systems can also be customized to fit specific item sizes and weights for greater flexibility in storage options. There is complexity in integrating with existing warehouse management systems, so it is best to work with warehouse automation professionals to ensure software compatibility.

Mini-Load Systems

Mini-load systems are a type of automated storage and retrieval system (AS/RS) that can handle small and medium-sized items in totes and trays. These systems operate at a high speed and can store items densely, making them a good choice for warehouses requiring rapid access to a large variety of stock. 

These goods-to-person systems are best used for lightweight items that can be quickly moved in and out of storage, so warehouses should consider the types of items being stored. 

One of the biggest benefits of mini-load systems is that they are easily scalable compared to other G2P systems. Additional modules can be added as needed, allowing this system to grow along with business needs. This system is not suitable, however, for extremely heavy or bulky items. For warehouses with larger items, a more robust AS/RS may be a better option.

Autonomous Mobile Robots (AMRs)

Autonomous Mobile Robots (AMRs) are the most revolutionary G2P solution in modern warehouses. These robots are dynamic, flexible, and transport items directly to human workers. They also easily integrate into existing warehouse workflows. 

AMRs like Prime’s goods-to-person robots use sensors and software to move shelves or pallets of goods through a warehouse from induction to storage, to picking and packing stations to shipping areas. AMRs speed up the fulfillment process by eliminating human and forklift bottlenecks and automating primary and secondary workflows. These robotic systems are easy to scale with business needs. These robots can also operate in even the most extreme conditions, lifting payloads of up to 4,400 lbs. or automating cold chain logistics operations down to -5°F. 

Because AMRs are powered by execution software, they can easily be reprogrammed to integrate with different workflows without needing structural changes. They also reduce human travel, manual handling, and the risk of injuries in the workplace. 

Final Thoughts

Choosing the right goods-to-person system for your warehouse depends on several factors including the items stored, order volume, and the physical layout of the facility. Carousel Systems and Lift Systems are great solutions for maximizing space while improving retrieval times, while Mini-Load Systems are optimal for high-volume, small-item storage. AMRs, however, bring unmatched flexibility and scalability to the most dynamic warehouses. 

Connect with a G2P expert today to find out how your operation can become a powerhouse of efficiency.