For the typical warehouse operation picking processes account for nearly 40-50% of total warehousing and distribution costs. Due to the significant financial impact picking is a critical area of focus for many supply chain operators. The supply chain industry is large and complex, as is each individual 3PL, warehouse, distribution center, manufacturer or retail that operates within it. For this reason there is no single picking method that will fit each individual supply chain. Any picking strategy or combination of picking strategies may be used. Some of the most commonly utilized picking strategies include batch, wave, cluster, piece, zone and sortation picking. The most basic picking strategy, piece picking, is the process of pulling inventory for a single order. The ratio for this method is one picker to one order. Batch picking is more complex. Using this method a picker will pull inventory from multiple orders into one large container or tote. Once all orders have been picked the inventory will be taken to a staging area where orders will be separated into their corresponding containers. Cluster picking is similar to batch picking in that multiple orders are picked simultaneously, but are picked directly into their corresponding containers rather than a group tote. This eliminates the added labor required to separate orders in the staging area. Wave picking is a method facilitated by warehouse management technology. Groups of orders are released in “waves” on a schedule to ensure labor is evenly distributed throughout the work day. Both wave length and frequency is determined by staff availability and daily workload. Zone picking is an inventory picking method where staff are designated to zones in the warehouse and only pick from those areas. Zones can be designated by groupings of SKUs or by aisle. Using this method multiple orders will be picked from each zone simultaneously. This method allows for inventory handling specialization by employee where necessary. Sortation picking is reserved for supply chain operations with the existing automated storage and retrieval system architecture. In this method inventory is brought to pickers via a conveyor system where they put items into their corresponding containers. This significantly reduces the labor hours required to complete order fulfillment activities. The final picking strategy is picking to box. In this method pickers remain at their designated station and place items into boxes as they move past on a conveyor system. Each box may visit multiple picking stations before order fulfillment is complete. To learn more about which picking strategy may be best for your business contact Datex for a no obligation operational assessment.

1. SUPPLY CHAIN
MANAGEMENT
BASICS:
INVENTORY
PICKING
STRATEGIES
BY: ANGELA CARVER

2. Supply Chain Picking Basics
• For most warehouse operations picking processes account for nearly
40-50% of total warehousing and distribution costs. For this reason
alone, picking is a critical area of focus for supply chain operators.
• Every 3PL, warehouse, distribution center, manufacturer or retailer
operates differently and will require different picking strategies to
help meet their specific business objectives. The most commonly
utilized inventory picking strategiesinclude:
• Batch picking
• Wave picking
• Cluster picking
• Piece picking
• Zone picking
• Sortation picking

3. Single Order/Piece Picking
• The most basic of picking strategies, piece picking, is the processof
pulling inventory piece by piece for a single order.
• This picking strategy is completed in a ratio of one warehouse picker
to one customer order.
1
1

4. Batch Picking
• Batch picking, also known as multi-order picking, is the process of
pulling stock to fulfill multiple orders concurrently. Once all of the
batched items have been picked, pickers will sort and stage orders
accordingly.
• This picking method helps to reduce travel time throughout the
facility and number of trips taken, reducing the average pick cost per
order.
1 2 31 2 3

5. Cluster Picking
• Cluster picking is a similar process to batch picking in that
warehouse staff pull inventory from multiple orders simultaneously,
but rather than picking into one community container items are
picked directly into their corresponding containers or totes.
• This eliminates the additional labor required to separate orders at the
staging/loading area.
1 2 3

6. Wave Picking
• Wave picking, most typically facilitated by your warehouse
management software, is a picking strategy where groupings of
orders are released throughout the day in “waves”.
• The timing of the these waves are scheduled to evenly distribute
labor throughout the day. Average wave length can range anywhere
from 1 to 4 hours, resulting in up to 8 waves per shift.
• The variance in wave length and frequency is determined by the daily
workload and available staff.

7. Zone Picking
• Zone picking is an inventory picking strategy where warehouse staff
pick solely from their designated zone. Depending on the size of the
facility and staff availability zones can vary in size from a few
grouped SKUs to full aisles.
• Pickers will pull inventory from their designated zone to fulfill multiple
customer orders.
• This strategy is used to increase picking efficiency and allow for staff
inventory handling specialization.
Zone
1
Zone
1
Zone 1
Zone 1

8. Sortation Picking
• Sortation picking, a strategy reserved for facilities utilizing automated
storage and retrieval systems (ASRS), requires little to movement for
the order pickers.
• Inventory is brought to the pickers via conveyor systems. This picking
strategy reduces order fulfillment labor requirements with system
automation.
1 2 3

9. Picking to Box
• The pick to box strategy is used most often in warehouse facilities
utilizing conveyor systems. In this strategy pickers remain at
designated stations and place items in boxes as the conveyormoves
them past. Each box may visit multiple stations before order
fulfillment is complete.

10. Conclusion
• Every order fulfillment operation will facilitate picking using a different
picking method, combination of methods or a customized method to
better fit their business.
• It is critical to have knowledge of a variety of picking strategies dueto
the constantly evolving supply chain and logisticsmarketplace.
• Implementing the best picking method can help to reduce average
order picking costs through improved efficiency, process
optimization and labor reduction.

11. Receive a no obligation operational
assessment to see which picking method is
best for your complex supply chain business.
Contact an Expert
http://www.southwestsolutions.com/industrial/types-of-picking-strategies-to-maximize-productivity-in-warehouse-operations
https://en.wikipedia.org/wiki/Order_picking
http://www.inventoryops.com/order_picking.htm