10 Best Warehouse Picking Methods for Efficient Order Picking
20-02-2020 14:34:09
  • Share Article

Warehouse order picking tools are an essential element of a warehouse. Similar to delivery, handling, and processing processes, order pickup forms compensate up to 55% of the operating costs in a distribution center. It will also have a direct effect on how happy the clients are. Your company will rise if the methods of picking in the warehouse are quick and accurate. You need to learn about order-gathering and how to apply good practices in the main warehouse-gathering.

Order selection is the method of choosing products from the company inventory to meet several customer needs. It's an essential part of a supply chain cycle and known to be the most labor-intensive and costly operation for every warehouse. As stated above, the price of order processing gets projected to be as large as 55% for all warehouse operating costs. Because order processing entails very high costs and, therefore, can directly impact customer satisfaction, businesses are thinking more about optimizing their process to build a more productive supply chain.

Types Of Warehouse Picking Methods.

1). Basic order picking.

About the method:

  • It is the most simple order-picking process, the product is placed at specific locations on even a static shelving and pallet rack. An order picker takes one item at a time, making the path across the row until the whole order gets grabbed.
  • Usually, your order picker is using some pickup truck. The architecture of the selection flow will be such that the order picker ends up very close to the actual point of reference. The pick report ought to have the picks sorted in the same series as fill flow. Fast-moving goods should be placed near the central cross-aisle or adjacent cross shelves to enable short cuts.

Equipment needed in this method – Static shelving is by far the most popular equipment for particle pick operations and is equipped with a depth between 12 "to 24." Static shelving becomes inexpensive, as well as the easiest method where there are choices per SKU or when the pieces are shallow.

2). Multi-order picking/ Batch picking

About the method:

  • During batch processing, several orders get organized into smaller batches. An order picker must pick all items in a single pass using a combined select list. Typically, the picker uses a multi-tiered pickup-cart to carry a different tote and carton on a cart of each shipment. Shipment sizes usually range from 4 to 12 items per shipment based on the average choices per order within the particular process.
  • Batch select systems might use comprehensive logic programmed that combines orders with the same products. In operations of low picks, batch picking will significantly reduce travel time by enabling the picker to make an additional pickup in the same region.

Equipment needed in this method:

  • As you develop, batch harvesting is becoming more complicated. Warehouse software will make it competitive by organizing orders to reduce SKUs and favor goods that are physically smaller.
  • The equipment used is lift trucks used to pick up pallets would depend on the layout of the building. Generic lift trucks have been used in bulk floor storage or broad aisle pallet rack processing in single range, push-back, ride-in / drive-thru, and flow system.

3). Zone picking

About the method:

  • A zone picker is the order picker variant of the assembly line. In the pickup zone, the pickup region split up as individual pickup areas. Order pickers will be allocated a particular zone and will only pick products inside that zone. Orders are transferred from one area to another as the selection from the previous zone is done (also called "pick-and-pass").
  • Conveyor networks typically used to transfer instructions from region to zone. While choosing an area, it is essential to keep up the number of picks from region to zone to retain a constant flow. Zones are typically wide enough to handle enough pickers of one or both order pickers. The development of quick pickup areas near the conveyor becomes essential for achieving higher profitability in zone harvesting.

Equipment needed in this method – A WMS will refine how instructions are sent to the departments, optimizing how often orders get loaded per change by switching large and small items appropriately. The main focus here is on productivity at the change level. Automated equipment is used to uplift the process.

4). Wave picking

About the method:
  • A twist on zone sorting and batch selection where, instead of orders going from one region to the next for processing, all areas get collected at the same time, and the products are then categorized and organized into individual items/shipments. Wave pick is the most comfortable option (shortest cycle time) to select several element requests, but the selection and aggregation process can be complicated.
  • Activities with a high overall number of SKUs or moderate or top picks per order can benefit from wave harvesting. Wave harvesting may be used to separate instructions from different routes or areas.

Equipment needed in this method – If it comes to arranging shipments at the right time depending on packaging, goods, distribution, and more, what a planner can require 30 minutes to work out might take only a few seconds for your WMS. The automation of a scheduled process is the most effective use of storage technology.

5).Discrete Picking

About the method:

  • In a distinct selection, instead of the employee allocated to a different "location" in the store, every piece of product required is collected in sequence, one line at a time. This strategy can fit well for a smaller team warehouse, which is not overloaded with complicated customer orders.
  • Although it may take time in the select field, the trade-off is that it reduces the number of keys to the order.

Equipment needed in this method – You could use the program to organize orders or change the arrangement of your items such that the worker automatically travels from either the back at the front of the activities while they gather merchandise. Robots are used to take care of the process.

6). Cluster Picking

About the method:

  • Efficiency seems to be the name of a cluster pick game, which requires a single picker collecting multiple items at a time, typically working with several SKUs. This approach will give you a serious leg-up if it comes to pace.
  • Still, you will have to incorporate different tools and services to make it successful in your store, including a sharp, excellently-trained picker, a portable cart, automatic machinery, and speech solutions.

Equipment needed in this method:

  • Robotics could be adapted very quickly to this model when you're up for investing. However, WMS makes it much easier to simplify the compilation of requests and the checking of each request such that you spend a lot of time doing manual tests as you merge it. In recent times, "robots" have joined the place-picking phase.
  • Most specifically, the Kiva robots used among Amazon. It is a part-to-picker technique, where robotics picks up a product rack and brings it to a station in which the order picker picks up what gets expected from either the rack.

7). Zone-Wave Picking.

About the method -
Zone-Wave Pick is a variation of strategies in which the pickers were allocated a zone and that each picker inside their region selects all the SKUs to all orders placed in that area, one order at a time with each scheduling period per move.

Equipment needed in this method
ASRS is a series of rack rows, every row providing a specific retrieval device that travels vertical and horizontal along with the rack. Carousels, Horizontal carousels were the same devices used among dry cleaners to hold and remove clothes. We have racks which can get designed to accommodate different types of storage bins.

8). Zone-Batch-Wave Picking.

About the method
–A most dynamic synthesis of all order select methodologies. Every picker shall be allocated a zone and shall select all SKUs to orders placed in an assigned zone. Besides, the picker chooses more than one SKU at the time, so there are several scheduling cycles every shift.

Equipment needed in this method –
As the size of the facility grows, WMS has become an essential part of activities. In such situations, this can help make sure that you have the best supplies available of all orders you are filling, make compromises for improving production and avoiding bottlenecks, and guarantee that you have everything arranged accordingly.

Scanners with bar-code – Bar-code detectors widely used for the select pallet activities.

Voice-directed pick-up – Voice technology also increased in an age in recent times and has become a very workable solution for particle select, case pick, and pallet pick operations.

9). Interleaving the job

About the method –
Project interleaving is a form of mixing pick or put-away. Warehouse Management Systems (WMS) using intuition to guide the lift truck driver to transfer the pallet to the next pick-up.

Equipment needed in this method
As described, motor pallet trucks, man-up ordering selectors & man-up turret trucks were the vehicles of preference for case-by-case operations.

10). Single Order Picking

About the method
The most common method of pick seems to be a single order pick. A picker collects one request at a time and heads to shop to locate each object on the list before finishing the application.

Equipment needed in this method
Flex rack of cardboard i.e Carton flow racks are identical to static shelving, but seeing as how tiny parts of the gravitation conveyor placed at a steep angle instead of racks. Carton flow racks are most effective as there is a vast number of selects per SKU.


Thus using different methods lead the process of picking order more efficiently. It saves cost and makes the process faster and more accurate.



Looking for more information? Explore more and discover how our solutions & services can help your business succeed.

Get a free consultation

Isourse provides end-to-end solutions for the supply chain & e-commerce industry that aims to digitize business processes with Industry 4.0 ready plans.

4th Floor, Ishram Signature,Plot No.- 5,Sector 13 Dwarka New Delhi - 110075

Copyright © 2023 Isourse Technologies All Rights Reserved. Privacy Policy