Let’s face it. In many cases, warehouse staff spend hours of their shifts maneuvering zones empty-handed.
Whether it’s suboptimal task management or poor route planning, these seemingly trivial issues inhibit business growth and might snowball into larger problems like decreased order accuracy or delayed shipments.
Task interleaving is a solution being adopted by ecommerce businesses to optimise crucial aspects of warehouse operations and improve overall efficiency across the supply chain.
With these techniques, employees follow more comprehensive routines based on efficient multi-tasking. In this article, we explore the concepts of task interleaving, its benefits, and how ecommerce businesses can adopt it.
What is task interleaving?
Task interleaving refers to the practice of combining different types of tasks into a single, continuous workflow. In the ecommerce and warehousing space, this could be things such as:
- Picking
- Put-away
- Replenishment
- Inventory checks
Instead of completing one type of warehouse task before starting another, workers or automated systems switch between these tasks based on proximity, priority, and efficiency.
A look behind the task interleaving curtain: How it works
The concept of task interleaving is based on optimising the efficient use of time and resources by minimising downtime and unnecessary movement. This is achieved in a few ways.
Strategic task combination
The first method involves strategic task combination. For example, a warehouse worker assigned to pick items for an order can also perform a put-away or replenishment task if it aligns with their current location. This reduces unnecessary movement and ensures that each trip through the warehouse serves multiple purposes, improving warehouse efficiency.
In environments using zone picking, where workers are confined to specific areas, task interleaving allows them to handle several tasks within their zone. A warehouse management system (WMS) plays a key role in managing this and assigning tasks based on location and priority.
Route optimisation
Optimising worker routes is another critical aspect of task interleaving. By assigning tasks in proximity to each other, the system ensures that travel time is reduced and workers can complete multiple tasks in a single trip.
For example, after picking an order, a worker might be directed to a nearby area for an inventory check. In wave picking, where orders are processed in waves, task interleaving helps maintain productivity by ensuring that activities like inventory checks or put-away tasks are assigned between waves, keeping workers active and streamlining warehouse operations.
Restocking and order picking
Instead of treating restocking and order picking as separate tasks, task interleaving enables workers to restock items while completing picks for an order. For example, if a worker is picking items in one aisle, they can be assigned to restock nearby shelves as part of the same trip.
How task interleaving benefits warehouse operations
As a method designed to minimise or nullify idle time, there are many benefits of task interleaving to ecommerce businesses whose warehouses employ this practice.
Boosts operational efficiency
The first benefit is a boost in operational efficiency. Instead of making multiple trips, workers can complete several tasks in one go, which minimises unnecessary travel. In a typical warehouse, as much as 50% of a worker’s time can be spent walking between tasks.
Task interleaving can significantly reduce this downtime by optimising task assignments. This leads to faster order fulfilment and increased throughput, enabling warehouses to handle more orders in less time, resulting in productivity gains.
Improves order accuracy
By integrating picking tasks with other activities like restocking or put-away, task interleaving ensures that inventory is consistently managed, which reduces the chance of stock discrepancies.
A well-managed warehouse, with accurate real-time inventory updates, means fewer errors in order picking. For instance, when workers perform replenishment and picking in tandem, they’re more likely to notice and correct potential stock issues before they lead to errors.
“One of the biggest reasons we went with ShipBob is the multiple checks from start to finish. The WMS makes it really hard to send out the wrong product. It still happens on rare occasions – but it happens a lot less than before. Before we implemented ShipBob’s WMS, our order accuracy rate was around 92%. Now we’re at 99.7% for order accuracy, which equates to 2,100 less mispicks a year on average.”
– Jourdan Davis, Operations Manager at Pit Viper
Promotes scalable adaptability
Task interleaving offers significant flexibility, making it easier for warehouses to adapt to fluctuating demand. During peak seasons, such as holidays or special promotions, a scalable interleaving strategy allows businesses to handle increased order volumes without sacrificing efficiency.
As demand grows, more tasks can be seamlessly interwoven into the workflow without overwhelming workers. With effective warehouse management, this scalability allows warehouses to adjust their operations without requiring drastic changes.
Unlock task interleaving with ShipBob’s warehousing tech
As a warehouse optimisation specialist, ShipBob offers comprehensive solutions to budding and thriving ecommerce businesses.
From outsourced fulfilment and automated inventory management to advanced automation, ShipBob caters to all sorts of businesses.
Faster order processing
ShipBob’s automated warehouse management software was designed to make decisions for you, eliminating the need to manually create, group, and distribute orders.
But faster order processing doesn’t come at the cost of accuracy. The system conducts a triple verification scan of each process, checking the storage location, the barcode of each stock-keeping unit, and the order’s picking container before approving and issuing any orders—thereby improving order accuracy.
Reduced idle time
With ShipBob’s WMS, employees are automatically assigned tasks. Smart task scheduling significantly reduces downtimes, as employees know where to go, which materials to use, and which products to handle at all times.
Improved resource utilisation
Ecommerce businesses partnering with ShipBob benefit from automated distribution of tasks that leads to optimised usage of labour, equipment, and warehouse resources.
ShipBob’s WMS issues picking orders by establishing priority levels based on criteria such as expiration date or batchable bulk orders, significantly reducing waste of resources and wear on physical goods.
Additionally, with comprehensive batch-packing stations in our fulfilment centres, ShipBob enables its partners to greatly increase their completed orders per hour (OPH).
Industry-leading ecommerce integrations
ShipBob’s logistics tech integrates seamlessly with major ecommerce platform partners. Whether you’re selling on Shopify, WooCommerce, Amazon, or another platform, ShipBob’s system ensures a smooth flow of information from the distribution centre to the customer.
Enhanced customer satisfaction
Businesses adopting ShipBob’s WMS solutions benefit from more productive employees and properly stored goods ready for shipment. Without delays and inaccurate deliveries, your customers have a much higher chance of turning into satisfied, returning buyers.
Get started with ShipBob
Interested in leveraging ShipBob WMS in your warehouse? Request a quote to connect with our team of fulfilment experts and get a customised quote.
Task interleaving FAQs
Here are frequently asked questions about task interleaving.
How does task interleaving improve warehouse productivity?
Task interleaving transforms downtime into productive time. For example, instead of driving a forklift empty (also known as deadheading), a worker will seamlessly switch to a secondary task like replenishing stock or moving a pallet of goods to another area of the warehouse. This ensures that every trip is purposeful, reducing wasted movement and improving overall warehouse efficiency.
Can task interleaving be implemented in small warehouses?
Even in small warehouses, task interleaving can streamline workflows by making the most of limited space and staff. By strategically aligning tasks, smaller operations can reduce bottlenecks and improve overall efficiency without needing major investments in additional resources.
What are the challenges of implementing task interleaving?
The main challenges of implementing task interleaving include the need for a well-integrated warehouse management system to coordinate tasks, employee training, and potential complexity in balancing multiple tasks without disrupting priority workflows.
