Two-step picking - LUCA Logistic Solutions

In this article we will deal with the topic of two-step picking and show you the advantages and disadvantages of the picking process.

What is two-step picking?

Two-step picking is a picking procedure in which order control and picking are not carried out immediately but in two steps. Depending on the storage type and storage zones, the shipping orders are combined into orders by the picker only at the final destination. The procedure is often supported by a sorting system.

How exactly does the procedure work?

The prerequisite for two-step picking is a certain quantity of individual sales orders that can be combined into a complete order (order pool or batch).

The merchandise management or warehouse management system cumulates the orders together and calculates the optimum combination of orders for picking. In this picking process, the volume of articles and containers must also be taken into account.

The storage type is decisive for management, or more precisely for shaft management in two-step picking. In intralogistics, the goods issue process and return storage are often supported by distribution systems (sorters) to simplify sorting when picking the second level.

First stage of two-step picking

In the first stage of the two-stage picking process, the picker collects as many articles (goods) as possible from a storage compartment in the warehouse zone, item by item. In this way, he saves on the routes through several picking zones (optimization of route times). The picker places the articles in one or more boxes (but it is not Multi-Order-Pickinga ).

The decisive factor here is that the order picker counts the correct number of items in relation to the article.

Second stage of two-step picking

When the picking (removal) of the articles in the warehouse is completed, the picker transports his boxes to a distribution station for sorting. Only there is order-oriented sorting to the individual sales orders. Each article is scanned and sorted by a distribution system.

The picking process is only completed after the two-step sorting.

Conclusion

To sum up. Two-step picking is very suitable for large total quantities. The advantage of the first stage is that the picker (order picker) can pick many articles from one storage compartment. A large total order is picked article by article. This saves the picker the distances involved. The disadvantage compared to single-stage picking is that the picker may have to count large numbers of items from a storage compartment, although an error is not very critical here.

In the second stage of picking, the articles are assigned to sales orders using a distribution system. To do this, each article is scanned and distributed. Two-step picking is very effective, but requires complex technical support and large total quantities of sales orders for the total order. Picking can also be carried out by untrained personnel.

The supporting systems

Two-step picking is not feasible without the support of picking systems. Various picking methods such as Pick-to-Light, Voice Picking, Pick-by-Point^®, Pick-by-Frame^®, etc. are used to support this process.

Further details can be found in the following articles:
Pick-to-Light - order picking with compartment displays
Voice Picking - voice-guided order picking
Pick-by-Point - the simple picking method with light
Pick-by-Frame - the innovation for Multi-Order-Picking

Comparable picking processes:

The following procedures are comparable:
Single-stage picking
Serial picking
Parallel picking
Series-oriented picking