5 Commonly Used Order Picking Methods for Warehouses of All Sizes

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When orders start flowing in exponentially and you run short on time, simply adding more labor to your warehouse might seem like a quick & logical solution. However, this might be nothing more than a temporary fix, especially when the growth is just an occasional spurt. With steadily increasing customer demands, sustaining efficient operations in the long run becomes critical to a well-functioning warehouse. Avoiding bottlenecks, ensuring accurate orders, and keeping up with customer expectations regarding shipping times becomes a lot more productive if you’re using the right methods & machinery in order picking. It is only when you execute absolute efficiency in order accuracy and timely order fulfillment, can you retain a customer. Here are 5 ways in which you can extract more out of your existing manpower by simply changing the way your order picker works.

  1. Single Order Picking
  • One of the most basic methods, a picker works on a single order at a time using machinery like a pickup truck or a reach truck. 
  • Each item is sorted and found out in the warehouse one-by-one in order to complete the respective order. 
  • This requires the worker to tread along the same route multiple times, thereby, reducing their efficiency.

Recommended for: Smaller warehouses with limited orders and smaller volumes.


1.       Batch Order Picking

  • The batch picking method combines products for multiple orders into one pick instruction so the pickers can execute the work on multiple orders in a single time slot. 
  • Rather than handling each order individually, a worker will pick all of the SKUs(items) required for the ‘x’ number of orders they are assigned, combine them and bring them all to a dedicated sorting area. 
  • Typically, the order picker uses a multi-tiered pickup-cart to carry a different tote and carton on a cart of each shipment. 

 

Recommended for: Warehouses with lots of SKUs and multi-product orders.


1.       Zone Order Picking

  • In this system, the warehouse is split into various zones. 
  • The work is uniformly divided amongst the pickers who are assigned their respective zones from where they must procure SKUs for various orders at a time.
  • In a slight variant called the “pick and pass method”, carts are transferred from one area to another as the selection from the previous zone is completed.

Recommended for: Warehouses that deal with high volume inventories and picker congestion.


1.       Wave Order Picking

  • This method is similar to batch picking, except that orders to be picked are assigned in ‘waves’ throughout the day. 
  • Wave picking allows warehouses to organize their operations in a way that takes factors like labor and transport schedules into consideration. Workers pick goods at the most optimal times, resulting in highly efficient operations.

Recommended for: Companies that have a higher number of picks with respect to each order.


1.       Cluster Order Picking

  • In this method, workers/order pickers are assigned clusters/groups.
  • A single order picker will cater to multiple orders simultaneously.
  • A worker will typically go around the entire warehouse loading items into a cart that contains multiple order containers. 
  • Instead of focusing on limited SKUs for several orders, pickers get to pick multiple items for limited orders. 
  • A cluster picking operation requires a sophisticated warehouse management system to ensure clusters are scheduled and assigned properly. The efficiency of Cluster picking is only as good as the system running it.

Recommended for: Increasing the number of goods shipped to customers on a given day.

Equipments to speed up the operation

Order picking, an otherwise strenuous and time-consuming job, can be greatly eased with the help of right equipments. Automated machineries such as the electric stacker or a diesel forklift can make a great difference in your order picking process. Using the right Material Handling Equipments, such as those from Linde MHE, makes for faster picking times, enhanced accuracy & recurring business. If you are not sure which equipment is the best choice for your particular needs, contact Linde MHE and we will gladly help you decide for yourself. 

 

 

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