The congestion caused by the above operation left unchecked will eventually fill up the available accumulation lines shutting down picking and shipping operations. Adding more accumulation conveyor will delay the problem, but not solve it.
A more cost effective solution is to test different batch picking strategies like limiting the pickers to no more than two batches at a time. You may also want to review critical path conveyor speeds to determine if they can and should be increased. And, make sure that the operation is in sync by having the right amount of labor at the right place at the right time. Forecasting software is available (perhaps already included with the initial WMS) that can optimize batch size and order release timing.
System Solutions for Improving Performance
Batch overlap is one of the most common problems associated with picking and sorting systems. Continuous-flow or waveless picking and sorting strategies, that can eliminate the need for segregated batches by expanding the capabilities of the WMS, may be a solution to increasing performance for some companies. Other possibilities are:
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