orderpicking

Order picking is the process of selecting items from stock to fulfill customer orders within a warehouse or distribution center. The goal is to retrieve the correct SKUs in the right quantities, verify accuracy, and prepare goods for packing and shipping while maintaining inventory integrity and efficient labor use.

The typical workflow begins with an order release from the order management system, followed by the generation of a pick plan that defines routing and method. Pickers locate items, collect them into totes or cartons, and then the picked goods are checked against the order, packed, labeled, and staged for outbound transportation. Inventory records are updated in real time to reflect movements and stock levels.

Common picking strategies include piece picking (single order picking), batch picking (collecting items for multiple orders simultaneously), zone picking (assigning workers to specific storage zones), and wave picking (synchronizing picking with shipping schedules). The choice depends on order profiles, item characteristics, and warehouse layout.

Technology and tools used in order picking include pick-to-light and voice-directed picking to guide workers, barcode scanning or RFID for verification, and wearable devices for hands-free operation. These are typically integrated with a warehouse management system or ERP to optimize planning, execution, and data capture.

Key performance metrics are pick rate, accuracy, travel distance, and order cycle time. Challenges include travel time, item location, stockouts, and product variety; solutions involve slotting optimization, ABC analysis, cycle counting, and selective automation. Effective order picking supports faster fulfillment, higher accuracy, and better inventory control.