PickbyScan

PickbyScan, or pick-by-scan, is a warehouse picking method in which workers use barcode scanning to identify and confirm items, locations, and quantities during order fulfillment. The process relies on a warehouse management system (WMS) to generate pick tasks and validate each action as items are selected, scanned, and packed. By replacing or supplementing paper pick lists with real-time scans, PickbyScan aims to improve accuracy and speed in order picking.

Typical workflow: A picker receives a pick task from the WMS, often organized into waves or orders. At each pick location, the worker scans the barcode on the bin, shelf, or item, and then scans the item’s barcode to confirm the exact product and requested quantity. The device compares scanned data to the pick list and, on success, updates inventory in real time. Any mismatch triggers an alert or a manual verification step.

Technology and components: The method relies on handheld barcode scanners or mobile devices, sometimes worn as rings or connected to heads-up displays. Barcodes or QR codes on items, containers, and locations are read by the scanner. The solution is integrated with a WMS or ERP and uses a wireless network to transmit data; many deployments use rugged hardware, cloud-based software, and mobile apps.

Advantages and considerations: PickbyScan can reduce mis-picks, improve inventory accuracy, shorten ramp-up time for new staff, and provide real-time visibility into fulfillment metrics. It requires reliable labeling, hardware maintenance, software integration, and staff training. Challenges include barcode damage, scanning errors, network reliability, and upfront costs. It is often used alongside other picking methods such as voice or light systems.