A pick zone is an area in your warehouse specifically designed for fast-moving products. Unlike general zone picking, a pick zone is a dedicated space where your most frequently picked items are stored for quick access, with each picker designated an assigned zone to streamline their workflow. This area improves picking speed and accuracy by putting high-rotation products in ergonomic, easy to reach locations. Assigned zones help streamline the picking process by allowing each worker to specialize in their respective area, ensuring efficient and organized order fulfillment.
The pick zone concept splits your warehouse into two areas: the pick zone (for daily picking) and a bulk storage area (for replenishment). Items in the pick zone are regularly restocked from bulk storage so pickers always have inventory available.
Modern warehouse management systems like PULPO WMS maintain pick zones by creating replenishment tasks when inventory levels get low. No manual monitoring required.
Zone picking divides the warehouse into zones based on product types, picking frequency or special handling requirements. The pick zone is the most critical of these zones - where your fastest moving products live.
When orders come in, they flow through relevant zones and the pick zone handles the highest volume of activity. Each-picker adds items and then passes the order to the next zone. This way of picking cuts down walking time and speed.
Order picking works better with properly designed pick zones. Workers don’t have to walk the entire warehouse for common items, optimizing the overall warehouse operation.
Zone picking assigns specific warehouse areas to individual workers, forming a zone picking system that enhances efficiency. The pick zone requires more staff than other zones due to higher activity. Orders that need items from different zones either flow through zones in sequence or get picked at the same time.
The steps in zone picking are:
Orders enter the system
Warehouse management system assigns picks by zone
Zone workers pick their items, starting in the pick zone for fast-moving products
Products merge at a packing area
Orders ship out
Zone picking creates clear responsibilities for each worker. They only focus on their zone and get faster and more accurate.
Inside the pick zone concept is the "golden zone" - the optimal height range for item placement. This area, between waist and shoulder height, minimizes physical strain and maximizes picking efficiency.
The golden zone reduces bending, reaching and stretching. Your most frequently picked items should be placed in this ergonomic sweet spot.
In a well designed pick zone the golden zone might contain:* Items picked multiple times a day
Best sellers
Lighter weight items that move frequently
Placing these high-demand items in the golden zone within your pick zone is the fastest and most efficient way of picking.
The sequential zone picking method (also called pick and pass) moves orders through zones one after another. A picker in one zone picks items and puts them in a tote. Then they send it to the next zone for more picking.
Sequential zone picking usually starts in the pick zone where most orders need items. The tote flows through the zones, gathering all needed items.
Sequential zone picking creates a smooth flow. Orders end up at a packing station complete and ready to ship.
In sequential zone, orders follow a set path. Each picker adds their items and then passes the order to the next zone.
Sequential zone picking reduces errors as workers focus on fewer products. It’s good for orders with items across multiple zones.
In simultaneous zone picking multiple pickers work on the same order at the same time. Each picker stays in their zone, with dedicated pickers in the pick zone for fast-moving products.
After picking, workers bring items to a central packing area. There they combine all items from different zones into complete orders.
Simultaneous zone picking speeds up order fulfillment. With multiple pickers working at once complex orders finish faster.
Simultaneous zone is best for orders with items from many zones. This prevents bottlenecks that can occur in sequential zone picking.
Zone wave picking combines zone and wave picking. Workers pick all items in their zones for multiple orders during one scheduling period or "wave".
The pick zone handles the largest volume during these waves due to the concentration of fast-moving items.
In this method pickers handle multiple orders within their zones. Zone wave picking processes large batches efficiently.
Zone wave picking helps large warehouses during peak periods. It groups picking activity into scheduled waves, making workload planning easier.
Zone wave picking balances efficiency with accuracy. It's good for large warehouses with many SKUs.
Zone batch pickinghas pickers pick items from their zones for multiple orders at once. In the pick zone this is particularly effective since many orders need items from this high-rotation area.With zone batch picking workers pick multiple orders in one trip through their zone. This reduces wasted movement in the warehouse space.
Zone batch picking works well for warehouses with many similar orders. It makes the picking process more efficient through better planning.
Zone batch wave picking combines multiple strategies. Pickers pick many items for multiple orders that need to ship within one scheduling period.
This complex zone picking method is suitable for warehouses with high order volumes. It maximizes efficiency by combining zone, batch and wave picking benefits, with the pick zone handling the highest volume of activity.
The zone batch wave picking approach requires strong warehouse management systems. These systems coordinate the complex movement of products through various zones.
Zone picking offers flexibility for warehouses with changing customer needs. Warehouse managers can adjust zone assignments based on order patterns, expand or contract the pick zone as demand changes.
This picking strategy adapts well to seasonal changes. Zones can expand, combine or reassign as needed to handle varying workloads.
You can add more workers to busy zones during peak times. This flexibility ensures steady output despite changing demands.
When employees work in one zone consistently they learn products in their area extremely well. Workers assigned to the pick zone become experts on your most important products.
Workers in a specific zone memorize exact item locations. They don't waste time checking maps or searching for products.
This focused knowledge makes your warehouse more efficient. Workers pick faster when they know their zone inside and out.
Zone picking reduces walking time dramatically compared to other picking methods. With a dedicated pick zone for fast-moving items workers spend less time walking for the most common picks.
Less walking means more actual picking time. This efficiency boost improves productivity especially in large warehouses.
Workers waste less energy on unproductive movement. They can maintain higher picking rates throughout their shift.
Zone picking improves order picker accuracy by limiting the range of items each worker handles. With fewer SKUs to manage pickers make fewer mistakes.
Workers in a designated zone become experts at identifying their products correctly. The pick zone with its focus on high-volume items sees the greatest accuracy improvements.
The picking process becomes more reliable when workers know their items thoroughly. Each zone can also implement specialized quality checks.
Deciding how to design your pick zone depends on:* Fastest moving SKUs
Order patterns and frequencies
Warehouse space
Staff availability
Product characteristics
When implementing a pick zone, warehouse managers should consider these factors. The design should balance accessibility with space efficiency.
Your pick zone should be near packing areas to minimize travel for your most common items.
Historical order data helps set up the pick zone. By analyzing picking patterns, warehouse managers can see what products really belong in the pick zone.
Data shows which products are ordered most frequently. This helps create a logical pick zone for maximum efficiency.
Your zones based design should put the most frequently ordered items in the pick zone. Within the zone, organize products by complementary picking patterns.
A good WMS like PULPO WMS is necessary for pick zone management. The system should track inventory, create replenishment tasks and monitor performance.
WMS optimizes pick paths within each zone. It also ensures the pick zone never runs out of stock by automating the replenishment process.
When implementing zone picking, choose a system that automates replenishment. The system should alert workers when pick zone inventory needs to be restocked from bulk storage.
Look for a WMS with real-time tracking. This will help spot and fix problems before they affect shipment times.
Proper training ensures workers know their role in both picking and replenishing the pick zone. Employees need to learn:
Pick zone boundaries
Products in the pick zone
Picking procedures and technology
Replenishment from bulk storage
Well trained staff is key to a successful pick zone implementation. Regular refresher training helps maintain efficiency as product mix changes.
Train separate teams for picking and replenishment to avoid role confusion. Pickers should focus on filling orders, while replenishment staff keep the pick zone stocked.
Store fast moving products in easy to access locations in the pick zone. Heavy items at waist height to reduce strain and improve picking speed.
The "golden zone" for picking is between waist and shoulder height. Put your most picked items in this range to reduce bending and reaching.
Organize the pick zone logically by picking frequency. This will make the picking process more efficient and reduce worker fatigue.
When a pick zone bin or position is low, it must be refilled from bulk storage.
A modern WMS like PULPO WMS creates replenishment tasks when inventory in the pick zone drops below threshold levels. So picking can continue uninterrupted.
Consider setting min/max levels for each pick zone location. This creates a buffer for peak periods.
Replenish during slower picking times to avoid congestion in the pick zone during peak hours.
Safety first in pick zone operations. Ensure the zone is well lit, ventilated and trip free.
Train workers on safe lifting techniques especially for high volume picking in the pick zone. Regular safety audits help identify and fix issues before they happen.
Consider ergonomics when designing pick zones. Proper equipment and techniques prevent injuries and keep the team productive.
Monitor:
Picking speed in the pick zone
Order accuracy
Replenishment response time
Overall order fulfillment time
Labor cost per order
These KPIs help warehouse managers to identify areas for improvement in the pick zone strategy.
Compare with other zones to spot inefficiencies. Use this data to refine zone picking variables and overall performance.
Keep the pick zone clean and organized to support picking. Regular inventory audits ensure system records match actual stock levels.
Clear labeling of locations and products helps pickers to pick fast and accurate. Consistent organization standards simplify training and operations.
Schedule regular cleaning of the pick zone. Clutter and disorganization slows down picking and increases errors.
One big challenge in pick zone management is the high volume of activity in this area. The pick zone gets busy when other zones are less active.
Warehouse managers should regularly analyze picking data and adjust staffing as needed. Dynamic worker assignment can help to balance workload during peak periods.
Monitor queue times in the pick zone to spot bottlenecks. You might need to expand the pick zone or add more workers during peak times.
Replenish the pick zone without interrupting picking operations requires careful timing. Replenishment must happen before stock runs out but not during picking. Automated replenishment alerts through your WMS prevents stockouts. These systems can predict when replenishment will be needed based on order volumes.
One of the cons of zone picking is the need for continuous replenishment. Good systems and processes overcome this challenge.
Higher activity in the pick zone means congestion can become an issue. Too many workers in a small space reduces efficiency.
Clear procedures for movement in the pick zone reduces confusion. One way traffic patterns prevents workers from blocking each other.
Design the pick zone with wider aisles than other warehouse areas. This extra space accommodates the higher activity without creating bottlenecks.
Modern WMS optimizes pick zones by:
Directing pickers to exact item locations
Automatically triggering replenishment tasks
Tracking inventory levels in real-time
Providing performance data for continuous improvement
Identifying bottlenecks in the process
These are the basics for pick zone operations. They coordinate work between picking and replenishment for smooth workflow.
WMS like PULPO WMS adapts to your pick zone strategy as needs change. They provide data for ongoing optimization of product placement and workflow.
Radio frequency identification (RFID) enhances pick zone management by automatically tracking inventory levels. RFID reduces manual scanning and increases accuracy.
With RFID you can monitor pick zone inventory in real-time. This visibility helps to identify replenishment needs before stockouts happen.
Implementing RFID is expensive but pays off in efficiency. It's worth it especially in busy pick zones with high turnover.
Pick-to-light systems use LED displays to guide pickers to the correct items. These systems light up shelf locations, showing pickers where to find products in the pick zone.
Pick-to-light speeds up the picking process and reduces errors in the pick zone. The visual guidance eliminates confusion between similar products.
These work well in pick zones with many similar products. The lights eliminate confusion and speed up picking rates dramatically.
Pick zones improve inventory accuracy by concentrating fast moving products in a dedicated area. Workers become familiar with stock levels and can spot discrepancies quickly.
Regular cycle counting in the pick zone helps to maintain accurate inventory records. This is more manageable than counting the whole warehouse at once.The pick zone concept makes inventory management easier by separating fast and slow moving products. Each can be managed differently.
With a pick zone you can track the movement of your best sellers. This data helps you predict future demand and optimize inventory.
Warehouse managers can use pick zone data to make better purchasing decisions. Knowing which products move the most helps to prioritize restocking.
Picking rates in the pick zone improves labor planning. You can staff this area properly based on historical picking data.
Pick zone is beneficial for warehouses handling many fast moving products. By creating a dedicated area for high rotation products this strategy reduces walking time and improves efficiency.
Success of a pick zone depends on proper implementation and management. Warehouse managers must design the zone, implement replenishment processes and monitor performance.
Pick zone isn't right for every warehouse but it’s a scalable solution for operations with clear product velocity differences. Knowing how to integrate a pick zone with your overall zone picking strategy helps you choose the best approach for your needs.
Ask yourself these questions when considering a pick zone:
Do you have clear fast moving products that make up a big part of your picking?
Can your warehouse layout support a dedicated area near packing stations?
Do you have the systems to replenish from bulk storage?
Would your operation benefit from specialized picking areas?
If you answered yes to these questions, a pick zone might be the right warehouse management strategy for you to improve efficiency and accuracy.