Order picking is amongst the most important operations in warehouse and fulfillment processes. Requires the selection of specific items from stock to meet customer orders. With more orders to pick, more SKUs and shorter delivery times, it is critical to have an efficient order picking strategy to ensure productivity and accuracy.
The right picking method can reduce unnecessary movement, improve order accuracy, shorten fulfillment times and help warehouses make better use of their available resources.
What is Order Picking?
Order picking is the task of retrieving products from a warehouse or fulfillment center to complete customer orders. Various picking methods can be employed depending on the size of the warehouse, inventory characteristics, orders processed and fulfillment needs.
An efficient order picking system must be both quick and accurate, while making the best use of labor and keeping the operation cost down. It's not just about picking faster, it's about establishing a process which consistently delivers the right products to the right orders with minimal unnecessary movement.
So why is Order Picking so Important?
The order picking process directly affects the efficiency of warehouse and fulfillment operations.
Lowers the Warehouse Operating Costs
A good picking method can decrease warehouse workers' repetitive motion and the distance they cover. Optimizing picker productivity can be done by better routing and grouping of orders in order to reduce time spent to process each order.
Improves Order Accuracy
A well-designed picking process aids warehouse staff in selecting the right items and quantities to include in each order. By using WMS picking assistance, a barcode scanning system and well-defined picking procedures, there are even further opportunities to minimize manual errors.
Speeds Up Order Fulfillment
Faster and more organized picking allows orders to move more quickly from storage to packing and dispatch. This is especially crucial for ecommerce businesses where faster delivery is becoming a key expectation of consumers.
5 Best Order Picking Strategies
No single picking method is right for all warehouses. The choice of the best order picking strategy will be decided on the basis of the number of orders, number of SKUs, warehouse design, product type and speed of the fulfillment.
1. Discrete or Single Order Picking
In discrete picking, one picker will pick one order at a time, picking all the required items for that order and then moving to the next order.
It is one of the easiest picking systems to have in place and works well for smaller warehouses, moderate order volumes, relatively few SKUs, or operations where the orders are quite distinct from each other.
2. Batch Order Picking
In batch picking, a picker makes one picking trip and picks products for several orders. Like or common SKUs can be grouped into an order.
This will lower repetitive movements through the warehouse and can increase productivity if a high order volume is placed on the warehouse with similar products.
3. Cluster Order Picking
Cluster picking enables worker to pick multiple orders in one picking trip. Individual products are loaded into individual totes, bins or compartments according to each order.
Cluster picking is different to batch picking, where the products can be picked together and sorted at the end of the picking process.
4. Zone Order Picking
Zone picking divides the warehouse into specific picking zones and assigns specific pickers to each zone.
When products are ordered from more than one zone, they are picked in the respective zone. It works well for larger warehouses, those that have more SKUs and complicated order profiles.
5. Wave Order Picking
Wave picking is available to schedule picking orders into "waves" or windows. Orders may be organized by delivery dates, carrier delivery dates, warehouse locations or priority.
This can have the effect of synchronizing pick and packing, dispatch and transportation schedules, especially in warehouses where the cut-off for shipping needs to be carefully coordinated.
Zone-Batch-Wave Picking
These methods can also be used in conjunction with each other for high volume operations. Zone-batch-wave picking assigns pickers to specific zones, groups multiple orders and specifies picking windows.
More complex approach and can be effective for a large WMS with high throughput, needs process coordination and warehouse systems being stronger.
How to Choose the Right Picking Method
The selection of picking method is determined based on the characteristics of operation of a warehouse. Businesses should consider several factors instead of just the volume of orders.
Order Volume
Many times a simple discrete picking operation works well in a low-volume warehouse, while other times a batch, zone, or wave or combination picking operation can be more productive in a high-volume warehouse.
Number and Characteristics of SKUs
For warehouses with a small number of SKUs, more straightforward picking operations might be necessary. Zone based picking or technology assisted picking can possibly be helpful for a large and complex SKU portfolio.
Order Profile
Businesses should look at the volume of items on an average order as well as the frequency of the same SKUs on orders. Batch picking should be used for similar and repetitive orders and cluster and zone picking should be used for diverse orders.
Warehouse Size and Layout
Another key factor to consider is the layout of the warehouse. Zone-based approaches work well in larger facilities with a spread of inventory, but not so much for smaller facilities.
Required Fulfillment Speed
Wave picking or a mix of picking methods can help to match warehouse activity to packing and carrier schedules if delivery time is critical.
Technology and WMS Capabilities
Technologies available should also factor into the decision. A Warehouse Management System (WMS) can instruct pickers, optimize picking routes, keep track of stock locations and even offer more sophisticated picking methods.
Ultimately, the best order picking strategy is the one that matches the warehouse's order profile, layout, inventory, technology, and fulfillment requirements.
Best Practices for Efficient Order Picking
With the correct picking method chosen, there are a number of practices which can be implemented in warehouses to further increase productivity:
- Apply WMS and barcode systems to pick and minimize manual errors.
- Improve the organization of the warehouse and the arrangement of products, minimizing unnecessary movements.
- Use appropriate material-handling equipment based on product and warehouse requirements.
- Regularly check picking performance for bottlenecks and process optimisation.
- Consider 3PL fulfillment when specialized infrastructure, technology, and operational expertise are required.
Conclusion
Optimizing order picking is crucial for cost control, accuracy and quick order fulfillment. There are various strategies available such as discrete picking, batch picking, zone picking, cluster picking, wave picking and combined picking, depending on the needs of the business.
More important than it is to select the most complex picking system, it is to select the right order picking strategy for the warehouse. Assessing order volume, SKU attributes, warehouse design, fulfillment needs and technology capabilities can help develop a picking process that enhances productivity and enables seamless, scalable warehouse operations.
