Warehouse picking is the process of retrieving items from their various storage locations within a facility to fulfill customer orders. It involves locating the required products, collecting the correct quantities, and organizing them for the next stage, which is packing and shipping. This process begins once an order is received and represents the physical start of order fulfillment.
The Importance of Picking in the Fulfillment Process
The efficiency of order picking directly influences a company’s operational costs and customer satisfaction. An effective process ensures orders are assembled quickly and accurately, which leads to faster shipping and delivery. This speed and precision help build customer loyalty and reduce expenses from correcting mistakes, processing returns, and managing complaints.
A streamlined operation also minimizes worker travel time through the warehouse and reduces the chances of sending the wrong item. This not only lowers labor costs but also supports the overall financial health and reputation of the business.
Different Types of Picking Methods
Piece Picking
Piece picking, also called discrete picking, is a method where a worker gathers items for one order at a time. The picker uses an order list to collect all items for a single order before moving to the next. This approach is easy to implement and is common in smaller operations or those with a low number of stock keeping units (SKUs). Focusing on a single order makes it simpler to track accuracy.
Batch Picking
Batch picking involves a single picker gathering items for multiple orders simultaneously. The worker collects a “batch” of the same item needed for several different orders in one trip to that item’s location. This method reduces the total travel time a picker spends walking through the warehouse. It is effective for businesses with a high volume of small orders or frequent orders for the same popular products.
Zone Picking
In zone picking, the warehouse is divided into sections or “zones,” with each picker assigned to work exclusively in one area. If an order requires items from multiple zones, it is passed from one zone to the next in a “pick and pass” system. Alternatively, workers can pick items for the same order simultaneously from their respective zones, with the items later combined at a consolidation point. This strategy is effective in large warehouses as it limits each picker’s travel area.
Wave Picking
Wave picking releases orders to the floor in groups, or “waves,” at scheduled times. This method often combines elements of zone and batch picking. A wave might group orders by a common shipping carrier, delivery route, or urgency. Pickers collect all items for all orders within that wave, which are then sorted for shipping, allowing the warehouse to synchronize picking with packing and truck departures.
Key Tools and Technologies Used in Picking
Warehouses use a range of tools to execute picking strategies, from manual aids to automated systems. The choice of technology depends on the picking method and the scale of the operation. These tools include:
- Paper pick lists, which are printed documents detailing the items and locations for an order.
- Handheld radio frequency (RF) scanners, which display tasks and allow workers to scan barcodes to confirm accuracy in real-time.
- Voice-picking systems that provide instructions through a headset, leaving a worker’s hands and eyes free.
- Pick-to-light systems that use illuminated displays on shelves to guide pickers to the correct item and quantity.
- Autonomous Mobile Robots (AMRs) that transport shelves to a stationary worker or move items between zones, reducing manual travel.
Core Responsibilities of an Order Picker
The primary responsibility of an order picker is to accurately and efficiently select products to fulfill customer orders. Their duties begin with receiving a pick ticket or digital order and reviewing it for the specific items and quantities required. They navigate the warehouse, sometimes using equipment like pallet jacks or forklifts, to locate and retrieve products from shelves and bins. A picker is also responsible for verifying that the pulled items match the order’s specifications, such as SKU, size, and color.
After picking, they may pack the items, apply shipping labels, and shrink-wrap pallets. Pickers also contribute to general warehouse organization by restocking inventory and helping maintain a clean and safe work environment. Skills for this role include attention to detail, physical stamina, and comfort with technology like scanners.
Measuring and Improving Picking Performance
To ensure the picking process is effective, businesses track key performance indicators (KPIs). Two common metrics are pick accuracy rate, which measures the percentage of error-free orders, and picks per hour, which tracks the number of items or orders processed in a set time. These figures provide clear insight into the efficiency and precision of the operation.
Improving performance involves adjustments to the warehouse and its processes. One strategy is slotting, which organizes the layout to place frequently ordered items in easily accessible locations to reduce picker travel time. Another solution is implementing a Warehouse Management System (WMS), which is software that can direct pickers on efficient routes and manage inventory in real-time for fewer errors and faster fulfillment.