The 3 Most Used Picking Systems in Warehousing: A Detailed Guide

With the rise of automated storage warehouses, it’s required to understand which picking systems best align with specific operational needs.

But you don't have to go elsewhere to specify the details. This article delves into the three most commonly used picking systems in modern warehousing: Wave Picking, Batch Picking, and Zone Picking. It also highlights the critical role that equipment choice plays.

What is Order Picking in Warehousing?

Order picking refers to the process by which items are selected from inventory to fulfill customer orders. It’s a fundamental operation in warehousing, directly impacting fulfillment times, customer satisfaction, and overall warehouse efficiency.

In an automated storage warehouse, the right order-picking method not only enhances workflow but also ensures smoother integration of automation technologies like Warehouse Management Systems (WMS) and robotics.

Choosing the wrong picking method can cause bottlenecks, increased labor costs, and delays. For any warehouse manager, it’s essential to analyze warehouse layout, workforce capabilities, and the nature of products when selecting the best picking method.

Wave Picking Method

Overview

Wave Picking is a dynamic process where workers collect items for individual orders in one efficient trip through the warehouse. It is one of the most streamlined methods for reducing time and distance traveled. In a wave-picking system, order pickers typically follow a designated path, optimizing the picking sequence to avoid retracing their steps.

Benefits

• Reduced travel time: By structuring the pick path, workers can eliminate backtracking, reducing walking distance.
• Adaptability: Works well with different warehouse sizes and layouts.
• Increased throughput: More orders can be fulfilled quickly as the picking process is streamlined.

Equipment Choice

When implementing wave picking, selecting the right equipment is critical. Lift trucks, carts, and scanners should be tailored to your warehouse's size and aisle configuration. Narrow aisle forklifts may be necessary if the aisles are tight, while standard pallet jacks or motorized carts can suffice for wider spaces.

The importance of using the right scanning equipment cannot be understated. Barcode or RFID scanners ensure real-time tracking of picked items, enhancing accuracy. Automated guided vehicles (AGVs) can also be integrated to further improve efficiency, reducing manual labor.

Batch Picking Method

Overview

Batch Picking takes wave picking one step further by combining multiple orders into one trip. Instead of handling a single order per picking run, the picker fulfills several orders in a single pass. After collecting items, the picked products can either be sorted into individual orders at a staging area or grouped directly during the picking process using bins or compartments on the picking cart.

Benefits

• Higher efficiency for smaller orders: Perfect for fulfilling multiple orders with few SKUs, significantly reducing overall picking time.
• Reduction in handling time: Items are only touched once and sorted as the picker moves through the warehouse.

Equipment Choice

For batch picking, the choice of cart design becomes particularly important. Carts should be fitted with bins or compartments that correspond to individual orders. This prevents errors and facilitates easy sorting. Additionally, warehouse management software (WMS) can further optimize the batching process by generating efficient pick lists based on product location and order details.

Another key consideration is the use of automated picking systems. In some automated storage warehouses, goods-to-person technologies can be employed, where robotic systems bring products to the picker, rather than having the picker navigate the warehouse. This significantly reduces walking time and increases picking speed.

Zone Picking Method

Overview

Zone Picking divides the warehouse into different zones, with workers assigned to pick items only within their specific zone. Orders may require items from multiple zones, but pickers remain in their designated areas. Products from each zone are then consolidated at a staging area before being shipped.

Benefits

• Efficient for large warehouses: In large facilities with varied inventory types, zone picking allows pickers to specialize in handling specific items, reducing the time spent moving between zones.
• Faster picking for high-volume warehouses: Zone picking ensures that multiple workers can pick parts of the same order simultaneously, improving throughput.\

Equipment Choice

Zone picking demands careful planning of zone layout and the appropriate equipment for each zone. For instance, refrigerated zones will need specific temperature-controlled storage equipment, while other zones might utilize standard shelving or pallet racking systems.

Picking technology like conveyors can help transport items from one zone to another, while voice-picking systems allow workers to receive real-time instructions without needing to look at screens or paper lists. Robotic picking systems can also be employed in high-density zones to increase picking speed and accuracy further.

Optimizing the Warehouse Pick Path

Regardless of the picking method used, optimizing the pick path is essential to improve efficiency. Factors that affect pick path optimization include the layout of the warehouse, SKU distribution, and aisle configuration. For example, placing high-frequency items near the packing area can reduce travel time.

Additionally, leveraging WMS software helps in continuously analyzing picking patterns to refine paths. Slotting optimization—which involves placing products in the most accessible locations based on their demand frequency—can be a game-changer, especially in automated storage warehouses.

Key Considerations

• Product location: Frequently picked items should be placed in easily accessible areas.
• Aisle configuration: Aisles should allow for smooth traffic flow without congestion.
• Traffic management: Consider the width of aisles and the turning radius of carts or lift trucks to avoid bottlenecks.

Quality Control in Picking Systems

In any picking system, quality control plays a pivotal role. Errors in order fulfillment can lead to customer dissatisfaction and costly returns. Quality control measures should be integrated into the picking process without adding excessive steps. Using barcode or RFID scanners during picking can ensure accuracy by verifying the correct SKU is picked in real-time.

In highly automated environments, automated sorting systems can ensure that items are properly staged before shipping, reducing the need for manual quality checks. This not only increases accuracy but also speeds up the picking process by reducing the number of human touchpoints.

The Role of Automation in Picking Systems

The integration of automation technologies has revolutionized warehouse picking systems. Automated Storage and Retrieval Systems (ASRS), robotics, and WMS software are becoming commonplace in large-scale operations. These systems optimize picking processes by analyzing data such as order volume, product placement, and labor availability, and adjusting workflows accordingly.

Automation can be especially beneficial when combined with the right picking method. For example, batch picking in an automated warehouse might involve robots handling the bulk of item picking, while human workers handle sorting and packing.

Conclusion

In a nutshell, Wave Picking is best for simple, small-scale operations, while Batch Picking can improve efficiency for multiple smaller orders. Zone Picking, on the other hand, is ideal for large, complex warehouses with diverse products.

The key to success lies in selecting the correct equipment to support each picking method.

But you don't have to fully burden yourself with those hard tasks. If you want to endorse the best warehouse practice or get a quote, don't hesitate to contact us now, our team of experts is ready to be at your service.