BatchPicking

Batch picking is a warehouse picking method in which orders are grouped into batches that are fulfilled together. In a batch pick, a single picker or a small team collects items for several customer orders in a single pass through the picking area, rather than fulfilling one order at a time. The concept aims to reduce travel time and improve labor productivity by exploiting commonality of items across orders.

In operation, orders are clustered according to criteria such as common SKUs, proximity of items, destination zone, or due date, and a batch is created. A pick list or digital display guides the picker through all items in the batch. As items are collected, they are placed into batch totes or sub-batches associated with each order. After picking, items are sorted and directed to packing for individual orders, or sorted later in a packing area.

Advantages include higher picking rates and reduced travel distance, better utilization of labor, and improved batch-level throughput, especially when many orders contain overlapping items. Batch picking can also improve service levels for high-demand items and small, frequent orders.

Challenges include handling complexity, risk of mis-picks across multiple orders, dependency on accurate WMS and real-time inventory, and the need to optimize batch size to balance batch carry and travel time. Delays or stockouts for one item can hold up the entire batch. In practice, batch picking is commonly supported by warehouse management systems with pick-to-light or voice-picking interfaces to guide operators and confirm selections.

Typical use cases include e-commerce and omnichannel fulfillment with many small orders containing similar items, fast-moving SKUs, and environments where travel time constitutes a large portion of the workday.