Before a box reaches your door, it navigates an ecommerce warehouse, where order pickers process your purchase. They locate the right items, ensure they have the right quantities, pack multiple orders, and use efficient picking methods to get through a long queue of orders.
When done right, every customer gets exactly what they ordered within the expected timeframe. Over time, first-time buyers turn into loyal repeat customers.
It all starts with order picking. Here are the various order-picking methods and challenges businesses face in improving warehouse operations for accurate and timely deliveries.
What is order picking?
Order picking is the process of retrieving products from a warehouse or storage area to fulfill customer orders. It involves locating the correct items, verifying quantities, and preparing them for shipment.
There are various order-picking methods, ranging from manually picking one order at a time to using advanced technologies like barcode scanners and radio-frequency identification (RFID). Each method offers unique advantages and is suited to different operational sizes, complexities, and requirements.
Order picking directly affects customer satisfaction. Accurate and timely order picking ensures customers receive the right products on time, fostering customer trust and brand loyalty. Efficient order-picking processes can also help reduce costs, minimize errors, and improve your warehouse operations.
Order-picking methods
- Single order picking
- Batch picking
- Zone picking
- Wave picking
- Pick-and-pass
- Pick-to-box
- Pallet picking
The order-picking methods in your warehouse directly impact efficiency and accuracy. You can combine methods to maximize benefits, such as using zone picking within a wave system or employing pick-and-pass strategies across zones. By understanding each method, you can create a hybrid approach tailored to your warehouse layout, order profiles, and business goals.
Here are seven picking methods that can improve your warehouse processes:
1. Single-order picking
Single-order picking—also known as piece picking or discrete picking—is a method where warehouse managers assign a single order to a picker who completes it before starting the next one.
This picking process is ideal for businesses with low order volume or special handling requirements, such as boutique clothing stores managing custom-tailored garments.
However, single-order picking can be less efficient than other methods, as it requires pickers to travel through the entire warehouse for each order, leading to increased walking time and potentially lower overall productivity.
2. Batch picking
Batch picking—also known as cluster picking—is a warehouse picking process where multiple orders are grouped and collected in a single trip.
This optimizes the picking process by reducing travel time and improving efficiency, making it an excellent choice for businesses with high volumes of orders sharing common items.
3. Zone picking
Zone picking is an order-picking process that divides a warehouse into distinct zones, each with designated products or categories. Pickers are assigned to these zones. When an order comes in, it’s split into smaller sub-orders based on the zones, and the pickers collect items for their respective sub-orders simultaneously. Pickers consolidate these sub-orders before shipping, resulting in faster and more efficient order fulfillment compared to single-order picking methods, where one picker handles an entire order from start to finish.
4. Wave picking
Wave picking is an order fulfillment process where managers schedule and release orders in timed waves throughout the day.
For example, you might have a morning wave for orders that came in the night before, a midday wave for morning orders, and an afternoon wave for orders placed before the cutoff time. This allows for better labor planning, reduced congestion in the warehouse, and the ability to prioritize orders based on shipping deadlines or customer service levels.
5. Pick-and-pass
Pick-and-pass is a picking strategy that uses a series of picking stations along a conveyor belt or similar system. Each picker is assigned a specific station and is responsible for picking a portion of the order before passing it to the next station, creating an assembly line process until the order is complete.
The pick-and-pass technique is especially effective for businesses with high-volume orders that require multiple items from different zones, as it speeds up order completion and reduces picker travel time.
6. Pick-to-box
Pick-to-box is a picking system where each picker uses a mobile cart with multiple boxes or totes, each representing a specific order. As the picker moves through the warehouse, they place items directly into the corresponding box or tote, keeping orders separate throughout the picking process.
This method enables pickers to fulfill multiple orders simultaneously, increasing efficiency and reducing the time spent on individual order processing.
7. Pallet picking
Pallet picking is a method used in fulfillment operations, where warehouse workers pick entire pallets of a single product instead of individual items to fulfill large orders or to restock picking locations.
This method is ideal for businesses that handle bulk orders or need to move large quantities of products quickly, as it minimizes the time spent on individual item handling.
Automated order-picking processes
Automated order picking is gaining popularity in warehouses and distribution centers due to labor challenges, ecommerce demands, and advancements in robotics and AI. It’s important to note that these systems are not fully automated by robots; rather, the instructions are automated, allowing workers to follow more efficient processes without having to read lists.
Here are a few automated order-picking methods:
Pick-to-light
Pick-to-light uses lights and displays to guide pickers through the picking process. When an order is ready, lights illuminate the shelves or racks where the required items are located, indicating the required quantity. Pickers confirm the pick by pressing a button or scanning a barcode.
Voice picking
Voice picking is a hands-free method that uses voice recognition technology to guide pickers through the warehouse. Wearing headsets with microphones, pickers receive verbal instructions on where to go and what to pick. They confirm actions verbally, which keeps their hands free for more efficient picking.
Mobile scanner picking
Mobile scanner picking uses handheld devices—like smartphones or tablets with barcode scanning capabilities—to guide pickers through the warehouse. The device displays order details, item locations, and required quantities. Pickers confirm each item by scanning its barcode and updating the inventory management system in real time.
Challenges of order picking
- Order accuracy
- Picker productivity
- Handling fragile or delicate items
- Technology integration
- Managing returns and reverse logistics
Effective order-picking methods boost efficiency and accuracy, yet implementing and optimizing these processes present significant challenges. By understanding these challenges and applying targeted solutions, you can refine your order-picking process and enhance overall warehouse performance:
Order accuracy
Ensuring order accuracy is crucial for customer satisfaction and reducing costs associated with returns and reshipping. However, human error, product similarities, and inadequate training can lead to mistakes in the picking process, resulting in customers receiving incorrect orders. Adopting technology-driven solutions, like pick-to-light or voice-picking systems, can reduce errors and improve order accuracy.
Picker productivity
Maximizing picker productivity helps to meet customer demands and keep operational costs low. Poor warehouse layout, product placement, and picking methods can hinder productivity, leading to longer order processing times and decreased efficiency.
By optimizing your warehouse layout, using appropriate picking methods, and providing ongoing training, you can boost picker productivity and streamline your order-picking process.
Handling fragile or delicate items
To prevent damage, some products require special handling during the picking process, which can slow the process and increase the risk of errors. Fragile or delicate items may need extra packaging, careful handling, or even separate storage areas.
To address this, implement specialized training for handling fragile items and use appropriate packaging materials.
Technology integration
Integrating new technologies into your order-picking process can be challenging, especially if your current systems are outdated or incompatible. Implementing new technologies often requires significant investments in hardware, software, and training, which can be costly and time-consuming.
Thoroughly research and select technologies compatible with your existing systems. Be realistic about the time it will take to train your team and introduce changes gradually to ensure implementation is successful.
Managing returns and reverse logistics
Ecommerce returns and reverse logistics can complicate the order-picking process, as they require additional handling, storage, and processing. Inefficient return handling can lead to increased costs, reduced inventory accuracy, and slower order processing times.
Streamline your returns process with a clear and efficient returns policy, a designated returns area, and technology like barcode scanning or RFID tags to automate tracking.
Order picking FAQ
How do you choose the right order-picking method?
The right order-picking method depends on order volume, product characteristics, warehouse layout, and available technology. An automated, high-tech picking method may work well for a large warehouse, but a small ecommerce brand selling one-of-a-kind vases might benefit from a simpler, more manual process.
What is an example of order picking?
An example of order picking is zone picking, where the warehouse is divided into separate zones, and pickers are assigned to specific zones to retrieve products for multiple orders simultaneously.
What is the most efficient order picking?
The most efficient order-picking method varies depending on a business’s requirements. Batch picking might be best for warehouses with high order volumes and similar products. By contrast, single-order picking could suit businesses with low order volumes or products requiring special handling.
