Order picking is the process of retrieving items from storage locations in a warehouse to fulfill customer orders. It is a fundamental component of the supply chain that directly influences how quickly and accurately products are delivered. With the growth of e-commerce, the efficiency of order picking has become a major focus for businesses aiming to meet customer expectations for rapid delivery.
What Is Order Picking?
Order picking occurs within facilities like warehouses and distribution centers. It involves collecting the specific items and quantities listed on a customer’s order from their designated storage locations. The effectiveness of this process has a direct effect on customer satisfaction, as accurate and fast picking leads to timely and correct orders, which builds loyalty.
The process can be costly, accounting for a significant portion of a warehouse’s total operating expenses because it is a labor-intensive activity. An error in picking, such as selecting the wrong item or quantity, can lead to returns and refunds, adding further costs and diminishing the customer experience. As a result, companies continually seek to refine their picking operations to improve performance and manage expenses.
Common Order Picking Methods
Piece Picking
Piece picking, also known as discrete picking, is a method where a picker collects items for one single order at a time. The worker receives a pick list and travels through the warehouse to retrieve each item until the order is complete. This approach is simple to implement, making it suitable for small businesses or operations with a low volume of orders. The primary advantage of piece picking is its high accuracy since the picker’s focus on a single order minimizes errors.
The main drawback is the amount of travel time involved, as a picker may have to walk the entire length of the warehouse multiple times a day. For larger operations, this extensive travel makes piece picking inefficient. It is best suited for companies that handle a limited number of SKUs (Stock Keeping Units) and prioritize accuracy over speed.
Batch Picking
In batch picking, a single picker gathers items for multiple orders simultaneously. The worker collects all the required units of a specific item for a “batch” of different orders before moving to the next item location. This method significantly reduces travel time because the picker only needs to visit each storage location once per batch. It is an effective strategy for businesses that process a high volume of small orders.
Once all items for the batch are collected, they are taken to a consolidation area and sorted into their individual orders. This additional sorting step is a consideration, but the travel time savings often outweigh it. Batch picking is particularly useful in warehouses where multiple orders frequently contain the same item.
Zone Picking
Zone picking divides the warehouse into several distinct areas, or zones, with pickers assigned to each one. When an order requires items from multiple zones, the order container is passed from one zone to the next until all items have been collected. This “pick and pass” system drastically cuts down on picker travel, as employees remain within their designated area. This method is highly effective for large warehouses with extensive inventories.
By having workers specialize in a smaller section of the warehouse, they become experts on the item locations within their zone, which can increase picking speed. The workflow is continuous, as multiple orders can be in process across different zones simultaneously. Zone picking is most beneficial for operations with a large number of SKUs and complex orders.
Wave Picking
Wave picking combines elements of both batch and zone picking. In this method, orders are grouped into “waves” that are released to the floor for picking at specific times throughout the day. These waves are scheduled based on criteria such as shipping deadlines, carrier pick-up times, or delivery destinations. A warehouse management system (WMS) is used to organize these waves for an efficient use of labor.
Within a wave, a picker might collect items for a single order or a batch of orders, and this can be organized by zones as well. For example, all orders for next-day air shipping might be scheduled in a morning wave to ensure they are ready for early carrier pickup. This method allows warehouses to coordinate picking with other operations, like packing and shipping, creating a synchronized workflow.
Tools and Technology Used in Order Picking
To enhance efficiency and accuracy, modern warehouses use a variety of tools and technologies. These tools are managed by a Warehouse Management System (WMS), the software that directs all warehouse activities.
- Paper pick lists are printed documents that list the items, quantities, and locations for an order. While simple, this method is prone to human error and lacks real-time tracking.
- Radio frequency (RF) scanners are handheld devices that allow pickers to scan barcodes on products and locations, confirming the correct item has been picked and updating inventory records instantly.
- Voice-directed picking systems provide instructions to pickers through a headset, who then confirm their tasks by speaking pre-defined commands. This hands-free system can improve both speed and safety.
- Pick-to-light technology uses lights on shelves to illuminate and guide the picker to the correct item location, where a display indicates the quantity to pick.
- Autonomous mobile robots (AMRs) can either guide pickers through the warehouse or travel to storage locations themselves to retrieve items and bring them to a central station for even greater efficiency.
The Role of an Order Picker
The primary role of an order picker is to accurately and efficiently retrieve products to fulfill customer orders. Their responsibilities begin with receiving a picking list, which can be a paper document or a digital file. Following the list, they navigate the warehouse to locate the specified items, verify the product and quantity, and transport the items to a designated area for packing.
An order picker’s job requires a specific set of skills. Attention to detail is needed to ensure order accuracy. The role is often physically demanding, requiring stamina for walking long distances and lifting items. Speed is also a performance metric, as the number of orders picked per hour impacts the warehouse’s productivity. A basic level of tech literacy is also needed to operate scanners, headsets, or other digital devices.
Key Challenges in Order Picking
The order picking process is filled with operational challenges. One of the greatest challenges is maintaining a high level of accuracy, as picking the wrong item or quantity leads to customer complaints and increased costs. Every mistake erodes customer trust and adds logistical expenses for processing returns and sending replacements.
Maximizing speed is another constant pressure. The time it takes to pick an order directly impacts how quickly it can be shipped. Inefficient routes, congested aisles, or time spent searching for items can create bottlenecks that slow down the entire fulfillment operation. Businesses must find ways to increase picker productivity to control labor costs. Addressing these issues involves selecting the most appropriate picking method and leveraging technology to support the workforce.