Developing a Successful Warehouse Picking Strategy

What you will learn in this blog

Fed up with inefficient picking in your warehouse causing delays and errors? You’re in the right place. In this post we will look at the top tips for developing a warehouse picking strategy that will transform your operations and productivity.

Ready to change your warehouse? Let’s get started and find out how to develop a warehouse picking strategy.

The picking process is the make or break of your warehouse. A good warehouse picking strategy is key to accurate and on time order fulfillment which is vital for customer satisfaction and loyalty.

Inefficient picking can cause a host of problems including longer order processing times, higher picking errors and lower productivity. These can lead to late shipments, unhappy customers and ultimately a hit on your bottom line.

On the other hand a good warehouse picking strategy can bring many benefits to your business including better inventory management, lower labour costs and increased operational efficiency. By optimizing the entire picking process, you can get goods flowing through your warehouse faster, order processing quicker and more accurate order fulfillment. This in turn can mean better customer satisfaction, increased brand loyalty and a competitive edge.

What are the different picking methods

Warehouse picking methods are the various ways of retrieving items from storage locations and assembling orders for shipment. The picking method you choose can have a big impact on the efficiency of the order picking process and your overall warehouse operations.

Discrete picking: the order picker retrieves items from their designated storage locations one order at a time. This is simple and easy to implement but can be time consuming and not the most efficient for high volume operations.
Batch picking: The order pickers collect items for multiple orders at the same time. This can improve efficiency by reducing the number of trips to the storage locations but requires careful planning and coordination to ensure the right items are picked for the right orders.
Zone picking is another method where the warehouse is divided into zones and each zone is assigned to a specific order picker. This can reduce travel time and improve productivity but requires a well organised warehouse layout and good inventory management.
There are also more advanced picking methods such as wave picking and cluster picking that use technology and data driven approaches to optimise the order picking process. Understanding the pros and cons of each picking method is key to choosing the right one for your warehouse.

What to consider when developing a warehouse picking strategy for the order fulfillment process

Developing a good warehouse picking strategy requires a holistic approach that takes into account many factors. By considering these factors you can create a solution that fits your warehouse operations.

Size and layout of your warehouse: The physical characteristics of your facility, such as number of storage locations, shelving height and overall warehouse layout can impact the best picking method. For example a large multi level warehouse may benefit from zone picking while a small single level warehouse may be better suited to discrete picking.
Nature of your inventory. The frequency of order fulfillment, volume of SKUs and characteristics of your products (e.g. size, weight, fragility) can all impact the picking strategy. For example if you have a high volume of small fast moving items batch picking may be more efficient than discrete picking. Manual picking methods can be labor intensive, leading to increased costs and potential errors. Automation can help reduce reliance on manual labor, enhance precision, and improve scalability in warehouse operations.
Level of technology integration in your warehouse: Integrating automation technology can greatly improve the efficiency and accuracy of your picking operations. Understanding the capabilities and limitations of the technology can help you choose the right solution for your warehouse.
Skills and capabilities of your warehouse staff: Factors such as employee training, task allocation and performance management can impact the overall effectiveness of your picking operations. A comprehensive training program and effective staff management can ensure your warehouse team is equipped to execute the chosen picking strategy.

Analyse order data to optimise order picking routes

Optimising picking routes is crucial for an efficient order fulfillment process. By analysing order data you can identify patterns and insights that can help you streamline the picking process and improve overall efficiency.

Order volume and frequency. By understanding the demand patterns for your products you can strategically layout your warehouse and inventory to reduce travel time and increase productivity. For example placing high volume items in easy to access locations can reduce the distance order pickers have to travel and get orders out faster.
Co-location of items that are ordered together: By grouping related products together you can reduce the number of trips to fulfill orders and make the picking process more efficient. This is particularly beneficial for batch picking or wave picking where order pickers can pick multiple items in one pass through the warehouse.
Historical order data: It can help you identify slow moving or seasonal items that may require a different storage or picking approach. By optimising the placement and handling of these items you can free up warehouse space and resources and focus on the high volume fast moving products that drive most of your order fulfillment.

Monitor and measure the picking strategy

Developing a good warehouse order picking strategy is an ongoing process that requires monitoring and evaluation. Monitoring and measuring the picking strategy is essential for any warehouse or storage facility to ensure efficiency and accuracy. By reviewing your picking operations regularly you can identify areas to improve, make data driven changes and ensure your strategy is aligned to your business goals. Here’s what to consider

Picking accuracy:

Measure the percentage of orders picked correctly without error. Accurate warehouse picking processes are key to maintaining high picking accuracy, which is essential for customer satisfaction and reducing returns and order corrections. By measuring picking accuracy you can identify where errors are occurring and implement targeted training or process improvements to fix them.

Order cycle time:

Measure the time from order received to order ready to ship. Measuring order cycle time can help you identify bottlenecks in your picking process and make changes to optimise the process. This could be optimising picking routes, adjusting staff levels or implementing automation to reduce time per pick.

Productivity metrics:

The number of picks per hour or percentage of on-time deliveries can also give you valuable insight into your warehouse picking strategy. These metrics can help you measure overall performance and identify areas to improve, such as warehouse layout or picking methods.

Warehouse Management System

To monitor and measure your warehouse picking strategy consider using a warehouse management system (WMS) or other data analytics tools. These will give you real time visibility into your picking operations so you can track KPIs, generate reports and identify areas to optimise.

By reviewing and adjusting your warehouse picking strategy regularly based on these metrics you can keep your operations agile, efficient and aligned to your business goals. This continuous improvement approach will help you stay ahead of the competition and deliver great customer service.

Choosing the right warehouse picking strategy

Effective warehouse picking strategies are the foundation of good order fulfillment and customer satisfaction. By understanding the picking methods, order data and managing your warehouse staff you can develop a picking strategy that will optimise your operations and set your business up for long term success.

As you start to optimise your warehouse picking remember it’s not a one off event but an ongoing journey of continuous improvement. Monitor your performance, gather feedback from your team and make data driven changes to your picking strategy. By creating a culture of innovation and adaptability you can keep your warehouse agile, efficient and responsive to your customers changing demands.

Use the power of a good warehouse picking strategy and unlock your warehouse potential. With the right approach you can transform your business, grow and become a leader in your industry. So what are you waiting for? Start your successful warehouse picking strategy today!

FAQs

What is a warehouse picking strategy?

A warehouse picking strategy is the methods and processes used to pick products from storage to fulfill customer orders. It’s about being efficient, error free and productive.

What picking method is best for a small warehouse?

For small warehouses with low order volumes or high product variability single order picking is often the best method as it’s simple and accurate.

How does batch picking improve efficiency?

Batch picking improves efficiency by allowing workers to pick for multiple orders at once, reducing travel time and increasing productivity.

What role does technology play in warehouse picking?

Technology plays a big part in making warehouse picking more efficient and accurate. Tools like barcoding systems, RFID and automated storage and retrieval systems make the process faster and error free.

What are the benefits of zone picking?

Zone picking improves efficiency by assigning workers to areas, reducing travel time and increasing productivity in larger warehouses with more product ranges.