7 Order Picking Methods - And how to improve it

In today's fast-paced world of logistics and e-commerce, efficient order picking is a crucial aspect of warehouse operations. As technology continues to advance, warehouses are increasingly adopting automation solutions to streamline their processes and improve overall productivity. In this article, we will delve into the world of order picking, compare manual and automated methods, and explore how warehouse automation is transforming the industry.

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What is order picking?

Order picking refers to the process of selecting and gathering items from a warehouse or storage location to fulfill customer orders. It involves retrieving the specified products from their respective locations based on the order details, such as item type, quantity, and specific customer requirements.

Order picking is a vital process within warehouses where items are selected from inventory to fulfill customer orders. Traditionally, this process relied on manual labor, where workers navigated the warehouse to locate and retrieve the required items. However, with the advent of warehouse automation, order picking has undergone a significant transformation.

For instance, warehouse automation technologies have revolutionized the order picking process, introducing a range of sophisticated solutions. These include automated storage and retrieval systems (AS/RS) such as AutoStore, robotic picking systems, conveyor belts, and advanced software algorithms. These technologies work collaboratively to streamline and optimize the order picking process, delivering numerous benefits.

Optimize order picking and improve warehouse efficiency

Optimizing order picking to improve overall warehouse efficiency offers several benefits:

Faster order fulfillment

By streamlining order picking processes, reducing travel time, and eliminating bottlenecks, warehouses can fulfill customer orders significantly faster. This results in shorter lead times and improved customer satisfaction.

Increased productivity

Optimized order picking methods, such as batch picking or utilizing automation technologies, improve productivity by reducing time wasted on unnecessary movements. This allows warehouses to handle higher order volumes and increase throughput without compromising accuracy.

Improved order accuracy

Efficient order picking processes minimize errors, reducing the likelihood of incorrect or missing items in customer orders. This leads to improved order accuracy, reducing costly returns, and enhancing customer satisfaction.

Enhanced inventory management

Optimized order picking is closely tied to effective inventory management. By implementing organized picking methods and utilizing technology like barcode scanning, warehouses can improve visibility into stock levels, reduce stockouts or overstocking, and enhance overall inventory accuracy.

Cost reduction

Optimized order picking helps to reduce operational costs. By streamlining processes, minimizing errors, and improving productivity, warehouses can reduce labor costs, minimize returns, and optimize resource allocation.

Scalability and flexibility

Optimized order picking methods and efficient warehouse processes provide scalability and flexibility to adapt to changing business needs. As order volumes fluctuate or new products are introduced, optimized picking processes can easily accommodate increased demands and changing requirements.

How to improve Order Picking

To improve order picking in your warehouse, these are the procedures you should be considering:

• Optimize your warehouse layout to minimize travel time. 
• Utilize technology like barcode scanning and pick-to-light systems. 
• Implement efficient picking strategies such as batch picking or zone picking. 
• Standardize procedures and provide training. 
• Continuously monitor and improve using key performance indicators.
• Foster collaboration and open communication among staff. 

By embracing these practices, you can significantly enhance the overall efficiency and accuracy of order picking in your warehouse, leading to faster order fulfillment, reduced errors, and improved customer satisfaction. Ultimately, these improvements will contribute to a more streamlined and effective warehouse as you strive to meet the demands of your customers and maintain a competitive edge in the market.

Different Order Picking methods 

There are several different order picking methods commonly used in warehouses. Some of the key methods include:

Piece Picking

In this method, individual items are picked one by one to fulfill each order. It is suitable for low-volume or customized orders but can be time-consuming. 

Batch Picking

Batch picking involves picking multiple orders simultaneously. Pickers collect all the required items for multiple orders in a single pass, improving efficiency and reducing travel time. 

Zone Picking 

In zone picking, the warehouse is divided into different zones, and each picker is assigned to a specific zone. Pickers are responsible for picking items only within their designated zones, optimizing efficiency and minimizing travel distance. 

Wave Picking

Wave picking involves grouping orders into specific time slots or "waves". Pickers focus on picking items for a particular wave during their assigned time slot, allowing for better coordination and improved efficiency. 

Cluster Picking

Cluster picking involves picking multiple SKUs or items that are frequently ordered together as a cluster. This method reduces travel time and improves picking efficiency.

Pick-to-Light and Put-to-Light

Pick-to-light and put-to-light systems use light displays and indicators to guide pickers to the correct items and locations in the warehouse, improving accuracy and efficiency.

Automated Picking

Various automated picking technologies, such as robotic picking arms, conveyor systems, or automated guided vehicles (AGVs), are used to perform picking tasks. These technologies can enhance speed, accuracy, and overall efficiency in the order fulfillment process.

The choice of order picking method depends on factors such as order volume, product characteristics, warehouse layout, and operational requirements. Usually, warehouses often utilize a combination of these methods to optimize their order picking processes.

Manual Picking vs. Automated Picking

Manual picking refers to the process of selecting or collecting items or products by hand, usually performed by human workers. It involves physically locating, inspecting, and retrieving the desired items from storage areas or shelves.

On the other hand, automated picking involves the use of technology, such as robots, conveyor systems, and computerized algorithms, to perform the picking tasks. Automated picking systems can be programmed to identify and retrieve specific items from predetermined locations, often utilizing sensors, cameras, or barcode scanning technology.

The key differences are that automated picking is faster, more accurate, scalable, and can save costs. Manual picking, on the other hand, offers flexibility for irregular or fragile items, meaning both picking methods offer pros and cons in warehouse operations.

How to measure Order Picking efficiency

To measure order picking efficiency, we recommend you consider these key metrics: 

• Order Picking Accuracy: Tracks the percentage of accurate orders picked.
  Calculation: (Number of accurate orders / Total number of orders picked) x 100 

• Order Picking Rate: Measures the number of lines/items picked per hour or per picker.
  Calculation: (Number of lines/items picked / Total picking time) or (Number of lines/items picked / Number of pickers) per hour  

• Order Picking Time: Monitors the time taken to complete the order picking process.
  Calculation: Time taken to complete the order picking process for each order 

• Travel Distance: Evaluates the total distance traveled by pickers during order picking.
  Calculation: Sum of travel distance for each picker or order

• Fill Rate: Assesses the percentage of ordered items successfully picked and included in each order.
  Calculation: (Number of items successfully picked / Total number of items ordered) x 100 

Regularly monitoring and analyzing these metrics can help identify areas for improvement, optimize processes, and enhance overall warehouse performance.
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Conclusion

In conclusion, order picking is a critical process within the logistics and warehousing industry that plays a pivotal role in ensuring efficient and accurate fulfillment of customer orders. As businesses face increasing demands for fast and accurate delivery, optimizing order picking strategies becomes imperative for maintaining a competitive edge. 

Do you want to learn more about how to automate your warehouse operations to improve efficiency and overall ROI? Let's get in touch today.

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FAQ 

What Is Order Picking?

Order picking is the process of selecting and gathering items from a warehouse or storage location to fulfill customer orders. 

What Are the Different Order Picking Types? 

There are multiple types of order picking methods. Below are some of the most common:

• Discrete Order Picking: Involves picking items for one order at a time, ensuring accuracy but potentially resulting in longer fulfillment times. 
• Batch Order Picking: Involves picking multiple orders simultaneously, increasing efficiency but requiring sorting or segregation of items afterward. 
• Zone Picking: Divides the warehouse into zones, with each picker responsible for a specific area, improving productivity and reducing travel time. 

Advantages of Discrete Order Picking:

• Ensures higher order accuracy. 
• Allows for better quality control. 
• Enables order customization and individual customer preferences. 

Advantages of Batch Order Picking:

• Increases picking efficiency and productivity. 
• Reduces travel time within the warehouse. 
• Enables order consolidation and streamlined packing.  

Advantages of Zone Picking:

• Enhances picking speed and efficiency. 
• Reduces congestion and eliminates unnecessary travel. 

• Enables specialization and expertise in specific zones. 

Advantages of Basic Order Picking:

• Suitable for smaller operations or low-volume picking.
• Cost-effective with minimal technology requirements.
• Allows for easy adaptation and flexibility.