Before the box arrives at your house, E-commerce warehouseAs an Order Picker, you fulfill customer purchases. Order Pickers find the right items, ensure the right quantities, pack multiple orders, and use efficient picking methods to handle long order lines.
If done right, every customer will receive exactly what they ordered within the expected time frame. Over time, first-time buyers will become loyal customers. repeater.
It all starts with order picking. Here we explore the different ways order picking can be done and the challenges companies face when trying to improve it. Warehouse operations Accurate and timely delivery.
What is Order Picking?
Order picking is the process of retrieving products from a warehouse or storage area to fulfill customer orders – finding the correct items, verifying quantities, and preparing them for shipment.
There are many different methods for order picking, from manually picking one order at a time to using advanced technologies like barcode scanners and radio frequency identification (RFID). Each method has its own advantages and is suitable for different operational sizes, complexities, and requirements.
Order picking is directly affected Customer SatisfactionAccurate and timely order picking ensures customers receive the right products on time. Customer Trust and Brand loyaltyAn efficient order picking process also helps reduce costs, minimize errors, and improve warehouse operations.
Order Picking Method
- Single Order Picking
- Batch Picking
- Zone Picking
- Wave Picking
- Pick and pass
- Pick to Box
- Pallet Picking
How you pick orders in your warehouse has a direct impact on efficiency and accuracy. You can combine multiple methods to maximize benefits, such as using zone picking within a wave system or employing a pick-and-pass strategy between zones. Understanding each method can help you create a hybrid approach that aligns with your warehouse layout, order profile, 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 in which warehouse managers assign a single order to a picker and have the picker complete that order before starting the next order.
This picking process is ideal for businesses with low order volumes or special fulfillment requirements, such as boutique clothing stores managing custom tailored garments.
However, single order picking can be less efficient than other methods because it requires pickers to travel the entire warehouse for each order, increasing walking time and potentially reducing overall productivity.
2. Batch picking
Batch picking (also known as cluster picking) is a warehouse picking process in which multiple orders are grouped together and collected in one trip.
This reduces travel time, improves efficiency and optimizes the picking process, making it a great option for businesses with large volumes of orders that share common items.
3. Zone Selection
Zone picking is an order picking process that divides the warehouse into zones and assigns each zone a designated product or category. Pickers are assigned to these zones. When an order comes in, it is split into smaller sub-orders based on zone, and pickers collect the items for each sub-order at the same time. Pickers then consolidate these sub-orders before shipping, allowing them to work faster and more efficiently. Order Fulfillment Compare this to the single order picking method, where one picker handles the entire order from start to finish.
4. Wave Picking
Wave picking is an order fulfillment process in which managers schedule and release orders in timed waves throughout the day.
For example, you can have a morning wave for orders that arrive the night before, a midday wave for orders in the morning, and an afternoon wave for orders that arrive before a cut-off time – allowing for better labor planning, less congestion in the warehouse, and prioritization of 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 to a specific station and is responsible for picking their part of the order and then passing it on to the next station, creating an assembly line process until the order is completed.
Pick-and-pass techniques are especially effective for businesses with large orders that require multiple items from different zones, as they speed up order completion and reduce travel time for pickers.
6. Pick to Box
Pick-to-box is a picking system in which each picker uses a mobile cart carrying multiple boxes or totes, each representing a specific order. As the picker moves through the warehouse, they place items directly into the corresponding boxes or totes, keeping orders separate throughout the picking process.
This method allows pickers to process multiple orders simultaneously, improving efficiency and reducing the time it takes to process each individual order.
7. Pallet picking
Pallet picking is a method used in fulfillment operations in which warehouse workers pick entire pallets of a single product, rather than individual items, to fill bulk orders or to replenish picking locations.
This method is ideal for businesses that need to process large orders or move large amounts of merchandise quickly, as it minimizes the time spent handling each individual item.
Automated Order Picking Process
Labor challenges, e-commerce demands, and advances in robotics and AI are making automated order picking more common in warehouses and distribution centers. It’s important to note that these systems aren’t fully automated by robots, but rather by automating instructions so workers can follow a more efficient process without having to read a list.
Here are some 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 and show the quantity required. The picker presses a button or scans to confirm the pick. barcode.
Voice Picking
Voice picking is a hands-free way to guide pickers through the warehouse using voice recognition technology. Pickers wearing headsets with microphones are told by voice where to go and what to pick. Pickers also confirm their actions by voice, freeing up their hands to pick more efficiently.
Mobile Scanner Picking
Mobile scanner picking uses handheld devices such as smartphones or tablets with barcode scanning capabilities to guide pickers through the warehouse. The device displays the order details, item location and quantity required. Pickers scan the barcode to identify the item and Inventory Management System in real time.
Order picking challenges
Effective order picking methods increase efficiency and accuracy, but implementing and optimizing these processes presents significant challenges. Understanding these challenges and applying targeted solutions can help improve order picking processes and improve overall warehouse performance.
Order Accuracy
Ensuring order accuracy is essential to increase customer satisfaction and reduce costs associated with returns and reshipments. However, human error, product similarity, and inadequate training can lead to mistakes during the picking process and customers receiving the wrong order. Implementing technology-driven solutions such as pick-to-light and voice picking systems can help reduce errors and improve order accuracy.
Picker Productivity
Maximizing picking productivity helps meet customer demands and keep operational costs low. Poor warehouse layout, product placement, and picking methods can reduce productivity and Order Processing It reduces time and efficiency.
By optimizing your warehouse layout, using proper picking methods, and providing ongoing training, you can improve picker productivity and streamline the 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 error. Fragile or delicate items may require additional packaging, careful handling, or separate storage.
This can be countered by providing specialized training on handling fragile items and using appropriate packaging materials.
Technology Integration
Integrating new technology into your order picking process can be challenging, especially if your current systems are outdated or incompatible. Implementing new technology often requires significant investments in hardware, software and training, making it costly and time-consuming.
Thoroughly research and select technology that is compatible with your existing systems. To ensure a successful implementation, be realistic about the time it will take to train your team and gradually introduce the change.
Returns and reverse logistics management
E-commerce returns and Reverse Logistics It can complicate the order picking process by requiring additional handling, storage, and processing. Inefficiencies in returns processing can lead to increased costs, reduced inventory accuracy, and slower order fulfillment times.
Streamline your returns process with clarity and efficiency Return Policydesignated return areas, and technology such as barcode scanning; RFID Tags for automated tracking.
Order Picking FAQs
How do you choose the right order picking method?
The right order picking method will depend on order volume, product characteristics, warehouse layout, and available technology. An automated, high-tech picking method may be appropriate for a large warehouse, while a simpler, manual process may be better suited for a small e-commerce brand selling unique vases.
What are some examples of order picking?
One example of order picking is zone picking, where a warehouse is divided into separate zones and pickers are assigned to specific zones to pick products for multiple orders simultaneously.
What is the most efficient order picking?
The most efficient order picking method depends on a company’s requirements. Warehouses with high order volumes and similar products are best served by batch picking. In contrast, businesses with lower order volumes or products that require special handling may be better served by single order picking.
