Order Picking in the Warehouse: Choosing the Right Strategy

Order picking is one of the most important processes in a warehouse or distribution center, making up the majority of operating costs and directly impacting service levels. Selecting and implementing the right picking strategy will ensure accurate on-time deliveries and cost-effective labor. In this article, we will review some different order picking strategies and how they can improve an operation.

Single Order Picking

One of the most common picking methods is single order picking. Just as it sounds, this method requires one order to be picked at a time, from start to finish, by a single operator. This method is easy to learn, does not require advanced technology, and is less prone to errors due to its simplicity. Single order picking is best suited for smaller warehouses or where entire pallets are picked. For larger and more complex operations, single order picking becomes inefficient due to the high amount of travel required throughout the warehouse.

Batch Picking

Opposite to single order picking, batch picking groups multiple orders together that have the same SKUs, which are later sorted by an operator before being shipped. The main advantage batch picking has over single order picking is the ability to pick multiple orders in a single trip, which improves operator productivity. Due to the increased complexity of batch picking, a warehouse management system (WMS) and order management system (OMS) are required to properly route and track orders throughout the warehouse.

Cluster Picking

For cluster picking, multiple orders are picked, from start to finish, by a single operator. This method is different than batch picking in that each order is sorted as it is picked. This is accomplished with the help of a cart containing individual totes for the operator to place SKUs in as they are picked. Cluster picking does not require a warehouse management system (WMS) and works best for smaller orders and smaller warehouses. This can create significant improvement from single order picking since the operator’s total distance traveled is reduced.

Zone Picking

With zone picking, the warehouse is split into individual zones that an operator will pick from. Operators will pick all the SKUs for an order in their zone and then send it to pack or the next zone if it is incomplete. This method can be used independently or in conjunction with the above-mentioned methods. This is a valuable option for high volume warehouses that struggle with operator congestion in aisleways.

Wave Picking

Wave picking can be utilized independently or in congruence with the above-mentioned methods. Wave picking groups orders together and releases them to operators in batches or “waves”. Orders can be grouped together based on a variety of different factors, such as shipping schedules, shift changes, product characteristics, etc. Wave picking is best suited for operations that are using batch or zone picking, already have a warehouse management system (WMS) and order management system (OMS) in place, and are looking to fully optimize their picking strategy.

Choosing the right order picking strategy is a great start to optimizing a warehouse operation. The best strategy will vary based on company size, inventory size, number of orders, SKUs per order and technological capabilities. At Establish, we combine a fact-based approach with state-of-the-art technology including warehouse simulations and data analytics to determine the optimal picking strategy for organizations.