Warehouse picking, also known as order selection, is the process of retrieving products from storage to fulfill orders. Choosing the right picking methodology for your warehouse operations is crucial for maximizing efficiency. Here are some of the most common warehouse picking methods to consider.
Batch Picking
Batch picking involves picker(s) fulfilling multiple orders in one batch. All the items for several orders are picked in one run. This method is efficient for high order volumes because pickers are not repeatedly returning to the same area for every individual order. Batch picking can lead to more picker errors so quality control is important. Using Lisman Forklifts like used order pickers for pick-to-light systems can help minimize mistakes.
Discrete Order Picking
With discrete order picking, pickers focus on fulfilling one order at a time from start to finish before moving on to the next order. This method works well for operations with relatively few line items per order. It also reduces confusion for pickers compared to batch picking multiple orders simultaneously. However, discrete order picking can be inefficient in facilities with high order volumes.
Zone Picking
With a zone picking system, a warehouse is divided into zones and pickers are assigned to specific zones. The picker only picks items from their assigned zone. This limits how much a picker has to travel throughout the warehouse. Zone picking improves organization and familiarity with certain products. But balancing workload across zones can be challenging.
Wave Picking
Wave picking divides order picking into “waves” scheduled for certain cut-off times. Pickers focus on fulfilling all orders in that wave during a specific time period before moving to the next wave. This allows for organized cut-off times and batching of orders. On the downside, wave picking can result in pickers waiting if all orders for a wave are not ready for picking at the same time.
Pick-and-Pass
With pick-and-pass, each item is picked one at a time and immediately handed off to the next workstation. This assembly line approach can achieve high throughput with minimal travel and waiting. However, pick-and-pass requires close coordination between pickers and relies on a constant flow of orders.
Consider Order Profiles
When evaluating picking methods, it’s important to consider your typical order profiles including order size, item size, order frequency, fulfillment speed requirements, and more. Larger but less frequent orders may benefit more from discrete picking, while smaller frequent orders favor batch picking. Zone picking works well for bulky or oversized items. Pick-and-pass thrives with a steady stream of similar orders. Analyze your order patterns to determine the best approach.
Leverage Warehouse Management Systems
Warehouse management systems (WMS) provide sophisticated solutions for optimizing pick methodologies. A WMS can introduce automation like pick-to-light systems, enable wave and batch picking efficiencies, track real-time workforce productivity, and much more. Integrating an advanced WMS with your warehouse execution processes can drive significant improvements.
As order fulfillment needs evolve, reevaluating picking methods is wise. There is no one-size-fits-all solution. The right picking methodology depends on your specific warehouse operations, order profiles, labor force, and business objectives. But optimizing order picking is one of the best ways to boost productivity, minimize costs, and enhance customer satisfaction.
