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Optimizing Order Picking: The 8 Best Methods for Warehouse Efficiency

Regardless of your industry, there are multiple order-picking methods that can help you improve your warehousing efficiency. Businesses that apply the proper picking procedures may significantly reduce expenses, improve accuracy, and increase overall production. This article delves into the eight best order picking techniques in warehousing, including the popular batch-picking method, and offers tips on how to improve your picking process.

At SPExpress, we offer efficiency, scalability, and comprehensive order picking, shipping, and warehousing solutions to businesses of any size, easing the burden on businesses. Get in touch with us right now to find out how our fulfillment and warehousing services may help your company.

Contact us today to learn how we can assist you with your inventory management and order fulfillment strategies. Together with our experts, you can start on the path to reliable and efficient inventory management right now.

What is Order Picking in Warehousing?

Warehouse order picking, also known as warehouse order picking, is the process of locating and retrieving products from storage areas to fulfill customer orders. It serves as a key link between inventory management and order fulfillment, with a direct impact on customer satisfaction and operational efficiency.

Order picking in the warehouse typically involves three key factors:

Pickers per order: The number of pickers working on a single order simultaneously.

Lines per pick: The number of orders for which a single item is picked at one time.

Periods per shift: The frequency of order scheduling during a single shift.

These factors play a crucial role in determining the efficiency and effectiveness of your warehouse operations. By carefully considering each aspect, you can tailor your picking strategy to best meet your specific needs and constraints.

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8 Best Order Picking Methods in Warehouse

Let’s look at the eight most effective order-picking methods:

Discrete Order Picking

Discrete order picking is the most straightforward and commonly used method. Discrete order picking is particularly suitable for small warehouses or those with a limited number of SKUs. It’s also an excellent starting point for businesses new to optimizing their picking processes, as it provides a clear baseline for performance measurement. In this approach:

  • One picker handles one order at a time
  • Items are picked one line at a time
  • There is only one order scheduling window per shift

Advantages:

Simple to implement and understand

Ideal for paper-based picking systems

Provides fast response time for order fulfillment

Easy to track individual picker accuracy

Disadvantages:

Less efficient due to increased travel time

Lower warehouse picking rates compared to other methods

Zone Picking

Zone picking divides the warehouse into specific areas, with dedicated pickers assigned to each zone. Zone picking is particularly effective in large warehouses with distinct product categories or storage requirements. It’s also beneficial when certain products require specialized handling or equipment.

Key features of zone picking include:

  • Pickers are responsible for items within their assigned zone
  • Orders requiring items from multiple zones are passed through each relevant zone
  • Also known as the “pick and pass” method
  • One scheduling period per shift

Advantages:

Reduces picker travel time

Increases familiarity with specific product areas

Can improve picking accuracy

Allows for specialization of equipment and processes within zones

Disadvantages:

Potential for bottlenecks if zones are imbalanced

May require additional equipment for zone transfers

Can lead to idle time if the order flow is inconsistent across zones

Batch Picking

Batch picking shines in environments with many small orders containing similar items. E-commerce fulfillment centres often benefit greatly from this method, especially when dealing with popular items that appear in multiple orders. Batch picking is an efficient method where:

  • One picker handles multiple orders simultaneously
  • Items are picked one SKU at a time for all orders in the batch
  • Ideal for orders with similar SKUs
  • One scheduling window per shift

Advantages:

Significantly reduces travel time

Increases productivity for orders with few SKUs

Efficient for small, physically similar items

Can dramatically increase picks per hour

Disadvantages:

Requires more complex sorting after picking

Potential for errors when sorting items into individual orders

May not be suitable for orders with large or diverse items

Cluster Picking

Cluster picking is particularly effective in warehouses with a mix of order profiles and those utilizing automated storage and retrieval systems. It combines the efficiency of batch picking with improved order separation, reducing the likelihood of errors during the sorting process. Cluster picking combines elements of batch picking with a focus on order containers:

  • Pickers work with multiple order containers simultaneously
  • Containers can be totes for order batches or discrete order shippers
  • Suitable for both manual and automated picking systems

Advantages:

Reduces unproductive travel time

Optimizes the use of vertical lift modules (VLMs) and carousels

Increases picking efficiency for similar orders

Can improve accuracy by separating orders during the picking process

Disadvantages:

Requires specialized equipment or carts

More complex to manage than simpler methods

May be less flexible for handling order variations

Wave Picking

Wave picking is particularly useful in operations with specific cut-off times for shipping or those dealing with a mix of rush and standard orders. It allows managers to prioritize time-sensitive orders while maintaining overall efficiency. Wave picking is similar to discrete picking but with a key difference:

  • One picker handles one order at a time
  • Items are picked one SKU at a time
  • Multiple scheduling windows throughout the shift

Advantages:

Allows for coordination between picking and shipping operations

Can optimize workforce allocation during peak times

Provides flexibility in order prioritization

Enables better control over order completion times

Disadvantages:

May lead to idle time between waves

Requires more complex scheduling and management

Can be less efficient than batch methods for small orders

Zone-Batch Picking

Zone-batch picking is ideal for large warehouses with a diverse range of products and high order volumes. It’s particularly effective when different areas of the warehouse require specialized knowledge or equipment. This hybrid method combines elements of zone and batch picking:

  • Pickers are assigned to specific zones
  • Within their zones, pickers batch pick for multiple orders
  • One scheduling window per shift

Advantages:

Combines the efficiency of batch picking with the organization of zone picking

Reduces travel time while maintaining zone familiarity

Suitable for warehouses with diverse product types

Can significantly increase picking rates compared to zone or batch picking alone

Disadvantages:

Requires careful zone balancing to prevent bottlenecks

More complex to implement and manage than single-method approaches

May require sophisticated warehouse management systems for optimal performance

Zone-Wave Picking

Zone-wave picking is particularly beneficial for warehouses dealing with diverse product ranges and fluctuating order patterns throughout the day. It’s also useful for operations with multiple shipping cut-off times or those serving various sales channels with different priorities. Zone-wave picking merges zone picking with wave scheduling:

  • Pickers are assigned to specific zones
  • Each picker handles all SKUs for all orders in their zone
  • Multiple scheduling windows per shift

Advantages:

Allows for precise coordination of picking and shipping schedules

Maintains the benefits of zone familiarity

Can adapt to varying order volumes throughout the day

Enables prioritization of specific product categories or order types

Disadvantages:

Requires sophisticated warehouse management systems (WMS)

May lead to idle time in some zones between waves

Can be challenging to balance workloads across zones and waves

Zone-Batch-Wave Picking

Zone-batch-wave picking is the ultimate solution for very large, high-volume warehouses with diverse product ranges and complex order profiles. It’s particularly suited to operations serving multiple sales channels, each with its own priorities and cut-off times. The most complex of all methods, zone-batch-wave picking combines all three approaches:

  • Pickers are assigned to specific zones
  • Within zones, pickers batch pick for multiple orders
  • Multiple scheduling windows per shift

Advantages:

Maximizes efficiency by combining the benefits of all three methods

Highly adaptable to various order profiles and volumes

Can significantly increase picking productivity in large, complex warehouses

Offers the greatest degree of control over the picking process

Disadvantages:

Requires advanced WMS and possibly automated systems

Complex to implement and manage

May be overkill for smaller operations

Requires extensive training for pickers and managers

How Can You Choose the Best Order Picking Method for Your Warehouse?

Choosing the best order picking method depends on various factors, including:

  • Warehouse layout and size
  • Product characteristics
  • Order profiles
  • Available technology and budget
  • Workforce skill level and adaptability
  • Shipping schedules and priorities

While discrete and zone picking methods may suit smaller operations or those with simpler product ranges, larger warehouses with diverse inventories may benefit from more complex approaches like batch or cluster picking. The most advanced operations might find that a hybrid method like zone-batch-wave picking provides the flexibility and efficiency they need.

Keep in mind that there’s no one-size-fits-all solution. The best picking strategy for your warehouse will depend on your specific needs, order profiles, and business goals. Regularly assess your picking performance and be prepared to adapt your methods as your warehouse needs change. This might involve small modifications, such as moving from discrete to batch picking, or more significant overhauls, like implementing a zone-based system.

Additionally, don’t overlook the importance of proper training and change management when implementing new picking methods. Even the most efficient system will fall short if your team isn’t fully on board and properly prepared.

To ensure continuous improvement in your picking operations, it’s also crucial to establish key performance indicators (KPIs) and regularly monitor them. Here are some essential metrics to track including:

  • Pick rate: The number of items or orders picked per hour
  • Picking accuracy: The percentage of orders picked without errors
  • Travel time: The amount of time pickers spend moving between pick locations
  • Order cycle time: The time from order receipt to shipment
  • Labour utilization: The percentage of time pickers spend actively picking versus other activities

Consistently measuring these KPIs allows you to detect bottlenecks, evaluate the performance of your selected selection process, and make data-driven optimization decisions.

By continually optimizing your order picking process, you’ll be well-positioned to meet the growing demands of today’s fast-paced supply chain environment. Whether you’re dealing with e-commerce order fulfillment, retail distribution, or complex B2B orders, the right picking method can make all the difference in your warehouse’s efficiency.

SPExpress is a trusted fulfillment partner that delivers seamless multichannel order fulfillment services to leading brands. Contact our team today to learn how we can help you optimize your hybrid fulfillment strategy.

SPExpress is committed to supporting your order picking needs, regardless of the size of your online store. Our expertise and resources can help you optimize your order fulfillment strategy and achieve your business goals.

At SPExpress, we offer efficiency, scalability, and comprehensive shipping and warehousing solutions to businesses of any size, easing the burden on businesses. Get in touch with us right now to find out how our fulfillment and warehousing services may help your company. Don’t let inventory problems ruin your company; work with us to find dependable, effective solutions that give you more control. We are ready to take your order fulfillment game to new levels.

Contact us today to learn how we can assist you with your inventory management and order fulfillment strategies. Together with our experts, you can start on the path to reliable and efficient inventory management right now.

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At SPExpress, we offer services from order fulfillment to supply chain management, which includes freight forwarding, transportation, warehousing, picking and packing, inventory and supply chain management, and order fulfillment. We work closely with our customers to ensure their 3PL needs are being met properly. We understand how valuable working with a reputable 3PL provider can be and how it can help our customers focus on growing their businesses. 

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