Warehouse picking is the process of retrieving products from storage locations to fulfill customer orders. A worker, called a picker, is tasked with locating and gathering the specific items listed on an order before they are sent to be packed and shipped. The goal is to collect the correct items in the right quantities to assemble a complete order.
The Importance of Order Picking
The efficiency and accuracy of order picking influence a company’s profitability and customer satisfaction. This process can account for more than half of all warehouse operating costs, so optimizing it leads to significant savings. Correct picking ensures customers receive what they ordered promptly, which builds trust.
Errors, like selecting the wrong item or quantity, can lead to costly returns and a damaged business reputation. A streamlined operation accelerates shipping and delivery to meet consumer expectations.
The Order Picking Process
The picking process begins when an order is processed by the warehouse’s management system. This system generates a pick list, a document or digital file detailing the items, their storage locations by aisle, rack, and bin number, and the required quantities. This list is then assigned to a picker.
Using the pick list, the picker travels to the designated storage locations. The picker verifies the item and its stock-keeping unit (SKU) number to ensure it matches the order. After confirmation, the picker retrieves the quantity specified on the list.
The pick is confirmed by scanning the item’s barcode with a handheld device, which updates inventory records in real-time. Once all items are collected, the picker transports the order to the packing area for shipment.
Common Warehouse Picking Methods
Warehouses employ different strategies to organize the picking workflow. The choice of method depends on factors like warehouse size, order volume, and product variety. These strategies are designed to minimize travel time.
Discrete Picking
Discrete picking is a straightforward method where a picker fulfills one order at a time. The picker uses one pick list to collect all items for a single order before moving it to the packing station. This approach is simple, ensures high accuracy, and is used by smaller operations with low order volumes.
Batch Picking
Batch picking involves gathering items for multiple orders simultaneously. A picker uses a consolidated list to collect items for several orders in one trip through the warehouse. This method reduces travel time and is suited for businesses with many orders containing a small number of items each.
Zone Picking
In zone picking, the warehouse is divided into sections, and each picker is assigned to work exclusively in one zone. Pickers retrieve only the items located in their assigned section for an order. For orders with items in multiple zones, the order is passed from one zone to the next until complete. This method is efficient in large warehouses with high order volumes.
Wave Picking
Wave picking combines elements of zone and batch picking. Pickers in each zone collect items for a group, or “wave,” of multiple orders simultaneously. These waves are scheduled at specific times to coordinate with other activities like shipping. This method maximizes efficiency and is effective in large, complex operations.
Technology Used in Order Picking
Modern warehouses use technology to improve picking speed and precision. A Warehouse Management System (WMS) assigns tasks to pickers and optimizes their routes. This software organizes and tracks all inventory and order fulfillment activities.
Pickers use Radio Frequency (RF) scanners to execute tasks from the WMS. These handheld devices allow workers to scan barcodes on products and locations, which confirms the correct item has been picked and updates inventory in real-time. This process reduces human error.
Other technologies also enhance efficiency. Voice-directed picking provides workers with verbal instructions through headsets, freeing their hands. Pick-to-light systems use illuminated displays on shelves to guide pickers to the correct location. Advanced facilities may use Autonomous Mobile Robots (AMRs) to transport goods to pickers.
Key Skills for a Warehouse Picker
Working as a warehouse picker requires several skills to perform the job effectively. These include:
- Attention to detail to accurately identify products and quantities to prevent order errors.
- Physical stamina for walking long distances and lifting items.
- Comfort with technology, including proficiency with handheld scanners, headsets, or other digital devices.
- Organizational and time management skills to work efficiently and meet productivity targets.