Picking methods

In practice, various picking methods have become established, which are used depending on the warehouse layout, order volume, and process requirements. The main differences between these methods lie primarily in the way orders are processed and the number of orders processed simultaneously.

Single-stage picking

In the single-stage picking , an order is picked in its entirety in a single pass. The picker removes all required items one after another from the warehouse and assembles them directly into an order.

Two-stage picking

The two-step picking divides the process into two steps. First, items are gathered or pre-picked; then they are assigned to individual orders.

Order-based picking

In order-based picking, each order is processed individually. The required items are selected specifically for that order.

Batch-oriented picking

In batch-oriented picking, multiple orders are processed simultaneously. Items are first gathered and then assigned to the individual orders.

Serial and parallel picking

In sequential picking, orders are processed one after another, whereas in parallel picking, multiple employees work simultaneously on different parts of an order.

• batch picking
• parallel picking

The various picking methods differ primarily in how orders are organized and the number of orders processed simultaneously.

There is a key difference between single-step and two-step processes. While single-step methods process an order in its entirety at once, two-step processes first perform a preliminary withdrawal before assigning the items to individual orders.

The distinction between sequential and parallel picking also plays an important role. Sequential methods are easier to organize, while parallel methods enable greater efficiency when handling large order volumes.

The choice of the appropriate picking method depends on various factors. These include, in particular, the structure of the orders, the number of items in the product range, and the desired throughput in the warehouse.

In warehouses with many small orders, a single-stage, order-based picking process can be effective. For large order volumes and recurring items, however, batch-based and parallel methods are more suitable.

In practice, different methods are often combined to achieve the most efficient picking process possible.

The choice of picking method is closely linked to the technologies used. While the method dictates the organizational structure, picking systems support its practical implementation in the warehouse.

Depending on the method, different technologies can be effectively utilized. For example, visual systems are often used in areas with high picking frequencies, while flexible solutions are employed in mobile processes.

• Pick-by-Light
• Pick to Light

The choice of the appropriate picking method depends on many factors, such as the structure of the orders, the variety of items, warehouse processes, and the desired throughput. Many warehouses combine different methods to achieve the most efficient order processing possible.

A thorough analysis of existing processes is therefore essential for selecting the appropriate picking methods. This analysis takes into account factors such as walking distances, order structures, picking frequencies, and organizational workflows. The goal is to design the picking process so that orders can be processed quickly, accurately, and cost-effectively.

Analysis and Selection of the Appropriate Picking Method

During a consultation, existing warehouse processes are analyzed in detail and opportunities for optimization are identified. Based on this analysis, we can determine which picking methods are best suited to the specific requirements.

Depending on the application, single-stage or two-stage processes, as well as serial or parallel picking, may be appropriate. The right combination of these methods contributes significantly to the efficiency and stability of the entire warehouse operations.

Optimization of existing picking processes

In addition to selecting the right method, the continuous optimization of existing processes also plays an important role. By making adjustments to the organization of order processing, it is possible to reduce walking distances, shorten turnaround times, and lower error rates.

Even as order volumes increase or requirements change, picking methods can be adapted to ensure a long-term efficient and scalable warehouse organization.