Top 7 Warehouse Order Picking Methods

Virginia Miller

July 2, 2024

In this article

The task of warehouse picking plays an essential role in any distribution process. Warehouse picking refers to the picking of products based on the order received. As special care is needed while picking up the right product requested in the order, the warehouse picker is specially trained for the task.

The cost incurred on warehouse picking amounts to more than 50% of the distribution costs. The work atmosphere will be good only when the warehouse picking system is planned perfectly and implemented. Hence, specific picking strategies must be implemented to reduce the cost.

What is the Picking Process in a Warehouse?

The picking process refers to the steps taken by warehouse workers to locate and retrieve items from inventory to fulfill orders. It typically involves the following key stages:

1. Receiving the Pick List

When an order comes in, a pick list is generated that details the specific items needed to fulfill that order. This list is provided to the warehouse picker assigned to the order.

2. Locating the Items

The picker uses the pick list to identify the locations of the required items within the warehouse. This may involve traveling to multiple areas and zones if the order contains a variety of products.

3. Picking the Products

Once at the correct location, the picker takes the necessary quantity of each item listed on the pick list. The picker may use carts, bins, or totes to gather multiple items at once before bringing them to the packing area.

4. Verifying Accuracy

Quality checks are performed to confirm each order is 100% accurate with no missing or incorrect items. Technology like barcode scanners can aid in the verification process.

5. Bringing Items to Packing

After picking is complete, the picker transports all items to the packing/shipping area so the order can be processed for delivery to the customer.

Warehouse Picking Strategies

There are a variety of order picking methods and strategies that warehouses can utilize to optimize the storage, organization, and retrieval of inventory. Choosing the right approach depends on factors like:

Order profiles and volumes
Product characteristics
Storage setup and layout
Staffing resources

Some top picking strategies include:

Discrete Order Picking

Each order is picked individually from start to finish before moving to the next order. This ensures accuracy but can be time consuming.

Batch Picking

All quantities of a particular product needed to fulfill multiple orders are picked in batches during a single trip through the warehouse.

Zone Picking

The warehouse is divided into zones, with pickers assigned to specific zones to improve familiarity with inventory locations.

Wave Picking

Orders are grouped into "waves" based on cut-off times and priorities, then picked in shifts by designated teams.

Conclusion

Now that you know about the different order picking methods, it's time to decide which one is right for your business. Keep in mind that the right approach depends on each company's unique operations, constraints, and objectives. Optimization tools can help identify cost-effective picking strategies tailored to a warehouse. If you need help getting started, don't hesitate to get in touch with our team at Simpl. We'd be happy to assist you with pick, pack and shipping!

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Recommended: How to Choose the Best fulfillment Warehouse Locations Near Me

FAQs

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What is order picking in warehouse fulfillment?

Order picking refers to the process of locating, retrieving, and consolidating items from inventory to fulfill customer orders. It is a critical warehouse operation that impacts accuracy, costs and service levels.

Why is an efficient picking process so important?

Picking often makes up the majority of labor costs in fulfillment. Minimizing trips, distance traveled, and other non-value added steps can boost productivity and lower expenses. Fast, accurate picking also leads to better customer experiences.

What are some common warehouse picking strategies?

Popular techniques include zone picking, batch picking, discrete order picking, wave picking, put-to-light systems, and more. The best approach depends on order profiles, product mix, facility design, and staffing.

How can you improve productivity in order picking?

Solutions like optimized slotting, hands-free technologies, intelligent routing, integrated software, and advanced metrics monitoring can significantly speed up picking workflows.

What picking errors are most common in distribution centers?

Frequent issues include shipping incorrect items or quantities, misplaced inventory leading to incomplete orders, and failing to follow first-in-first-out (FIFO) methods resulting in expired goods.

How can technology enable more efficient picking processes?

Warehouse management systems, wearable devices, pick-to-light and put-to-light systems, barcode scanning, mobile devices, and warehouse automation all streamline workflows.

What performance metrics are used to evaluate picking productivity?

Key indicators include pick accuracy, picks per hour/per worker, travel distance, inventory accuracy, peak throughput rates, and order cycle times.

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