5 Ways of Order Picking

In this post we explore the different way in which operatives can be utilised to pick orders in the most efficient way possible. The different methods detailed below all have their pros and cons however, they are all suited to different environments. In some cases, 2 or 3 of the below methods might well be used in the same warehouse, adding flexibility to the picking process that sticking rigidly to a single method might not allow.

1. Single order picking

Single order picking is exactly as the name suggests. An operative will travel through the warehouse retrieving all items needed to fulfil one order at a time. This picking system works well for smaller warehouses that handle simple orders. It can also be scaled up so that when an order is large enough it may be picked using single order pick – this is where picking method might be mixed.

2. Batch picking

Batch picking is the aggregation of multiple orders into the same consolidated picking list. This means that an operative would be sent to pick SKUs in bulk to fulfil the multiple orders on the visit to the pick location. This reduces the number of passes needed through the warehouse to retrieve the items. Batch picking is often then pair with a consolidation process. This could take the form of order sequencing the products to then be loaded onto a vehicle so that the driver can pick from the load. Or by simply loading the pallets or cages onto the vehicle to allow the driver to then pick from the load by being directed to the pallet/cage containing the correct stock.

3. Cluster picking

The cluster order picking method reduces the picking times in a similar way to the batch picking method. The difference here though is that the operative does a sortation at the time of pick. This is usually into a tote on a picking cart. Each tote represents an order, and the operative will pick items and place them into the tote for that order. The benefits here are that for orders that will fit in totes for example small items and multiple SKU’s or multiples of a single SKU then when the order come out of the picking area to be packed it is already sorted and does not need further consolidation.

4. Zone picking

With zone picking the warehouse or site is split into zones and dedicated operatives are assigned to each of the zones. Operatives fulfil orders within their zone by working through their pick lists. The most common scenario is that an order is picked into a carton and then passed onto the next zone to continue the pick operation. Once all zones have been picked the carton is passed onto a central consolidation area. The benefit here is that operative remain within contained zones reducing their travel times and increasing their familiarity with the zone they are working in.

Another practical application of zone picking is when temperature controls come into place. The zones are naturally split by frozen, chilled and ambient. Operatives will be dedicated to a temperature zone and multiple operatives will then process different part of the pick for the customer’s order. Unlike the first example there isn’t a central consolidation as ambient and frozen products cannot be stored or transported in the same temperature. However, they must all end up on the same vehicle to ensure they get to the end customer.

5. Wave picking

Wave picking is a variation on batch and zone picking and works particularly well in larger warehouses. Orders are typically grouped into waves based on certain factors or attributes such as delivery location, picking zones, delivery date, customer status, delivery requirements, service level agreements etc. This can then either be done by order or by batching the orders together. For example, some customers order maybe big enough to process once and then again later in the day if other products are added. Smaller orders could then be batched together into a wave to be processed by one operative and then passed to the consolidation area.

Wave picking can also be used when picking rounds or routes in multiple passes through the day. For example, if you are running a late afternoon or evening cut off for orders then the warehouse could pick the first wave of products before the cut off. Then pick a subsequent wave once the cut off has passed, adding the final items to the order before consolidation and then dispatch. This allows the warehouse to get ahead of the work and utilise the day more efficiently. However, used incorrectly this type of wave picking can lead to additional complexity or inefficiency if not used at the right time; too early and there won’t be enough product to make the wave efficient, too late and you will still be picking the first wave after the cut off.

All of the above ways of picking have their pros and cons and the key is working out, based on order profile, the best way to pick orders for your business. Sometime the best way is to have 2 or 3 methods employed on site to give maximum efficiency to the warehouse regardless of the order profile that comes through from the customer. With this in mind if you would like any advice on picking methods or a conversation about which methods you should employ and why, then please get in touch with us here at Bertle Fisher and we would be happy to help. We will also be posting additional posts about picking methods and warehouse setup so keep your eye out for our next posts.