Order Picking Strategies For a Warehouse

Best Order Picking Strategies, Tips, and Tactics

Learn how to improve picking speed with these order picking strategies that will boost efficiency in your warehouse’s picking processes and systems.

Check the Pick at the Slot Using Automation

Design your order picking process to include a double-check at each step. Human error is inevitable, so it’s essential to catch mistakes early. Ideally, errors should be detected while the picker is still at the slot, eliminating the costs of downstream corrections. To ensure accuracy, your system should include:

• A scan of slot ID barcode labels and product UPC codes.
• Blind entry of the quantity picked.

Tactics to Minimize Selector Walking

Reduce the need for excessive walking by using these tactics:

• Place slow-moving items in side aisles and only access them when necessary.
• Pick from both sides of the aisle, using smaller pick facings.
• Batch pick multiple small orders in one trip.

Ensure 100% Product Availability

Implement an optimized replenishment system to prevent empty pick slots. Avoid creating order delays caused by missing items before shipping. Use pick lists that only display in-stock items, so pickers don’t waste time adjusting inventory records for out-of-stock items.

Touch Picked Items Only Once

Each item should only be handled once during the picking process. Ensure accuracy during the first pick, so no further repacking, quality control, or shipping checks are required. The picked item should go straight into the truck after being touched by the original picker.

Segment Frequently Picked Items

Create a short pick line for your top-performing items. By placing the 10% of SKUs that fulfill 50% of orders in a condensed area, you can significantly reduce travel time. Slot the next 20% of items that account for 30% of orders just outside the short pick line. This strategy ensures that most orders can be fulfilled by traveling through only 15-20% of the warehouse pick slots.

Eliminate Pick-and-Pass Line Picking

Pick-and-pass methods slow down orders to the pace of the slowest picker. By switching to individual cart picking instead of conveyor picking, you can increase picking rates by 30-200%.

Warehouse Managers Must Lead the Commitment to Excellence

Focused management support for staff responsible for picking is the key to improving efficiency and accuracy. If managers demonstrate a strong commitment to optimization, staff will follow. A top-down approach is essential for boosting productivity and creating a culture of excellence.

Invest in Staff Training and Quality Circles

Warehouse productivity can suffer as customer requirements change. Your staff is your first line of defense against inefficiencies. Invest in training focused on improving productivity and accuracy. Introduce management-supported quality circles to identify problems and implement solutions. These practices lead to continuous improvement.

Need More Order Picking Strategies?

We hope this guide has provided valuable strategies to help you increase efficiency and learn how to pick faster. Implement these ideas to optimize your operations.

For more tailored advice, contact a warehouse optimization expert to design a plan specific to your operation.