The forgotten duo in warehouse efficiency: how sequencing and buffering save you both time and space

Anyone managing a warehouse today knows the pressures: peak times create stress, manual picking leads to higher error rates, and staging areas take up more and more valuable space. And just when everything should be running smoothly - picking, sorting, loading - the biggest delays occur. These are classic bottlenecks that cost many companies money, time and customer satisfaction.

By optimizing two processes, you create a surprising amount of impact: sequencing and buffering. And what if these functions are no longer separate processes, but can be integrated into one flexible and scalable system?

Sequencing during the picking process

Traditionally, sequencing - presenting orders or items in the correct order - is done only after picking. This requires additional sorting stations, quite a bit of manual work or complex conveyor lines. But with Exotec's Next Gen Skypod robots, it can also be done more efficiently: they automatically optimize the sequence while delivering the goods.

By integrating sequencing into the automated order process, each item arrives at the right place at the right time, fully coordinated with, for example, delivery routes or the order of shelf filling in the store. Fewer errors, faster shipping and no more extra packing or sorting before the packages go out the door.

Buffers without buffer zones

In addition, buffering - storing goods temporarily until they are processed or shipped - takes up separate space in many warehouses. That space is often static and not scalable. By integrating buffering into the racks themselves, a system like the Next Gen Skypod from Exotec automatically determine which items to store temporarily, without additional handling or loss of space. The warehouse robots not only pick all items, they do so in the correct order ánd only when instructed to do so. If buffering is required, the robots clearly follow the order so the packages don't get in the way anywhere.

That makes a huge difference, especially during peak periods: goods that are ready for shipment too early are parked in the system, rather than blocking the dock or taking up staging space.

From problems to a smooth process

The integrated approach to sequencing and buffering provides:

• A smoother order flow without manual sorting steps
• Better use of space, staging becomes redundant
• Fewer errors thanks to automatic sequence optimization
• Lower operating costs through less handling and fewer staff spikes
• Faster processing, resulting in shorter lead times and higher customer satisfaction

Flexible and scalable automation

Behind this approach is technology that has already proven its value in multiple industries. Exotec's Next Gen Skypod solution integrates robots, storage, sequencing and buffering into one scalable system. Operators pick directly into shipping boxes or bins, while the system automatically sorts, buffers and optimizes in the background. The result: more quiet on the floor, fewer errors, and a stronger ability to handle peaks.

At the French retailer E.Leclerc for example, this reduced the waiting time at the pickup point from 10-15 to less than 5 minutes per customer. It is a concrete demonstration of how integrated sequencing and buffering streamlines processes while serving customers faster. A Skypod System is currently being installed at Colruyt's Collect & Go, and since last year Auchan Retail has been very satisfied with the Skypod robots to prepare customer orders. Lyreco, Carrefour, Eltra and CEVA are also fans and have already optimized their warehouses with Exotec's robotics.

Ready to experience the difference?

For many warehouses, it is not an issue or there is lost space and efficiency, but where and when. By addressing those bottlenecks at the source, companies win in terms of both cost savings and customer focus. Sequencing and buffering are an often overlooked but strategic lever in this regard.

Want to know more about how to optimize processes in your warehouse? Read more about the Next Gen Skypod at www.exotec.com.