Automated Order Picking: Key Methods, Systems, & Strategies

This detailed guide discusses the various aspects Warehouse order picking: automation, functions, process, challenges, and the future outlook.

Warehousing involves numerous processes for successful order fulfillment continuously and efficiently. Warehouse picking is one of the key processes that defines when the right products are picked from the right place to fulfill the right order.

Let’s dig deeper into what is warehouse picking along with different order picking methods, warehouse picking systems, and more in this complete order picking guide

What is Order Picking in a Warehouse?

Warehouse order picking refers to the process where individual items/goods are picked from storage locations within the warehouse or distribution center to fulfill the customer orders.

Once the order is received and processed, the warehouse picker (either a person or an automated picking system) goes to the right location(s) in the warehouse and picks the items as per the order(s) in a cart or conveyor system.

Order picking is also known as warehouse picking or warehouse order picking in warehousing terminologies. Warehouse picking is one of the most important of all warehouse processes as it requires high operational costs, movement of goods, labor-intensive efforts, and investments in automated systems.

Different Warehouse Picking Methods

There are different ways in which an item can be picked to fulfill the order. Based on the warehouse’s size, customer demands, availability of manual labor, and the kind of inventory, choosing a picking strategy can be an important decision.

Choosing an efficient order picking method can drastically improve your warehouse productivity and ability to fulfill orders.

Wave Picking

A combination of batch and zone picking, wave picking is beneficial for large warehouses receiving multiple high-volume orders. In wave picking, a worker receives a combined order list and picks different items on the list in a single wave.

It allows warehouses to complete orders quickly and with less staff as the picker doesn’t have to go back and forth for picking items. Waves can be classified on parameters such as customer location, delivery date, order frequency, order types, etc.

Combining zone picking with wave picking creates an efficient warehouse workflow, especially for high-pick operations.

Batch Picking

Batch Picking is useful when there are multiple orders for the same SKU. The picker needs to go to the picking location only once and he can bring the required number of SKUs to fulfill multiple orders at the same time.

This warehouse picking process saves a lot of time in traveling to and from to get the same SKU multiple times and optimizes fulfillment operations.

Zone Picking

In zone picking, the warehouse is divided into different zones that are assigned to a dedicated worker. When an order comes in, each worker is responsible for retrieving SKUs placed in their zones only.

The carton is then passed over to another zone for picking SKUs present in that zone. Once all the SKUs are retrieved, the complete order is sent to a centralized place for packing.

It is suitable for completing orders quickly as the order gets divided into different zones and picking multiple SKUs for an order can happen simultaneously.

Discrete Picking

Discrete picking is the most common type of order picking in warehouse that is followed in most warehouses. Here, one picker is responsible for completing one order and travels around the warehouse to pick SKUs mentioned in the order.

It is a simple process that doesn’t have a fixed timeline to fulfill and depends on when the picker has completed picking the SKUs. Ideal for small warehouses and paper-based picking, this technique is the least efficient method of order picking and makes the warehouse slow.

Automating the Warehouse Order Picking Process

The global warehouse automation market is set to cross the $30 billion mark by 2026. It is easy to understand why warehouses are keen to automate their picking processes. Not only does automated warehouse picking provide several benefits but also helps warehouses to stay ahead of their competitors.

Integration of robotic or semi-robotic order picking systems, smart wearable devices, advanced data analytics, and machine learning algorithms assist pickers to complete the warehouse picking process quicker by automating repetitive and redundant tasks.

Warehouse picking automation has been on the rise in the last few years especially after the Covid pandemic and the situations arising by it necessitating the use of automated picking systems.

All in all, the warehouse picking automation industry is growing quickly, with innovations and new solutions being developed regularly.

Key Automated Picking Systems In Warehouse

There are a lot of different automated picking systems that can be incorporated in a warehouse to make it easier for the picker to fulfill orders quickly and efficiently.

These order picking systems or automated warehouse picking systems deploy modern warehouse technologies to assist the picker in finding the shortest route to an item, verify the items as per the order, and even perform certain repetitive tasks.

Pick-to-light

In the Pick-to-light automated picking system, LEDs are placed for every SKU distributed around the warehouse. Once an order comes in, the picker scans individual item barcodes attached to a temporary holding container, like a shipping carton.

The LED light attached to that item lights up automatically, guiding the picker to that item’s location.

Once the item is picked, a button is pressed to confirm the picking and the picker then moves on to the next illuminating area.

Voice Picking

Voice picking is an automated warehouse picking system that requires the use of wearable technology in the form of smart headsets. An order management system analyzes the incoming order and relays the best path for a picker to choose and pick items to fulfill the order.

It improves the accuracy and speed of order picking and eliminates the need for carrying handheld devices like barcodes and RF scanners.

Vision Picking

Using augmented reality, vision picking aims to make the automated order picking process 100% error-free. It employs a head-mounted display that has a wearable PC, an integrated camera, control software, and is connected to the warehouse management software system.

The integrated navigation system displays an optimized route for the picker to the exact location of the targeted SKU and verifies it visually as well. This order picking system with continuous quality control allows the warehouse to do fewer audits.

Robotic Picking

Cobots (collaborative robots) and autonomous mobile robots (AMRs) come under the category of robotic picking and are part of automated warehouse picking system. A robotic picking system is a warehouse picking automation system that helps to automate either some parts or the entire picking process in a warehouse.

These systems can improve the efficiency and speed with which items are picked and sent to the packing station. While cobots work in conjunction with the warehouse staff, AMRs can perform tasks independently, freeing up manual pickers.

Scanner-Based Picking

Mobile scanners are a great way for pickers to ensure that the correct item is picked to fulfill the order. Mobile picking can be achieved by attaching barcodes to every item in the warehouse.

Pickers receive a consolidated list of the items to be picked, an optimized route for all the items, and a quick verification if the item picked is correct as per the order or not.

This warehouse picking system decreases the time otherwise spent on moving around the warehouse and helps find correct items in the first go.

Common Warehouse Order Picking Challenges

Suboptimal Picking Routes

More than 80% of a worker’s time is spent on picking items from different parts of the warehouse to complete an order. This happens due to suboptimal order picking routes for every product, leading to delayed orders and customer dissatisfaction.

Inefficient Utilization of Workforce and Equipment

Since more than half the warehouse workforce is employed in the picking and packing process, effective utilization of the workforce is fundamental for an optimized flow of products.

High Rate of Picking Errors

For a warehouse aiming to increase productivity, picking error rates of 1-3% can prove to be costly. If a wrong SKU is picked for an order, it can lead to costly delays and decreased customer satisfaction.

Lack of Integration with Picking Devices and Warehouse Software

Warehouses that still follow redundant practices end up consuming a lot of time, money, and labor for every process.

Manual Task Allocation

Paper-based processes often lead to errors or mistakes while picking. Allocating tasks manually might work for a smaller warehouse, but can cause difficulties in larger operations.

Lack of Visibility in Picking Operations and Metrics

Warehouse managers are unable to track their pickers due to poor clarity about what is happening and what to do next.

Benefits of Warehouse Picking Automation

Automated order picking systems in warehouses can provide a number of benefits including improved efficiency, accuracy, and productivity, while also reducing labor costs and improving worker safety:

1. Efficiency and Productivity: Automated order picking systems can handle tasks faster than humans, increasing throughput.

2. Picking Accuracy: Reduces the chance of human error, leading to improved customer satisfaction.

3. Labor Savings: Helps save on labor costs by reducing the necessity for manual labor.

4. Space Optimization: Automated picking systems can optimize warehouse layout by storing items more efficiently.

5. Improved Worker Safety: Automates physically demanding tasks, reducing the risk of workplace injuries.

6. Scalability: Makes it easier to scale operations in response to demand changes.

7. Inventory Control: Improves inventory accuracy and control.

8. Reduced Training Time: Eases the training of new staff on order picking processes.

9. Performance Analysis: Enhances visibility for managers to analyze picker performance.

However, these systems require significant investment and ongoing maintenance.

Why Hopstack Can Be Your Next Order Picking Software

Hopstack’s cloud-agnostic AI-powered digital warehouse platform provides a perfect order picking software solution for every warehouse process right from receipt to dispatch.

Optimal Picker Routing: Uses advanced machine learning algorithms to calculate the optimal route for order fulfillment.

Smart Picklist: Enables dynamic picking, minimizing distance traveled and maximizing pick rate.

Picking Verification and Error Reduction: Utilizes checks and balances to reduce errors in picking.