Find the Right Picking Method for You!

Picking, or order fulfillment, is generally defined by (a) the number of pickers working on a single order, (b) the number of warehouse aisles, and (c) the frequency at which orders are scheduled during shifts.

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Now let’s look at the main picking methods:

1. Order Picking

The advantage of this method is its simplicity — the picker processes one order line by line.

This is the most basic and therefore most common picking method. The picker processes one order at a time, line by line. There is only one planning window per shift, meaning orders can be picked anytime during the day without scheduling constraints.

This method allows the use of paper pick lists, provides ample time, and makes it easy to monitor picker accuracy. However, it’s the least efficient approach.

2. Zone Picking

Each picker is assigned a specific area of the warehouse and is responsible for picking all items for all orders within that zone. If an order contains items from multiple zones, it is completed only after passing through all zones. This is also known as the “pick and pass” method.

There is only one planning period per shift. Any order received after the cutoff time is picked during the next shift.

3. Batch Picking

In this method, the picker handles a group of orders at once, picking one SKU at a time. It’s efficient when multiple orders include the same SKU — the picker makes one trip to collect all items for those orders.

The main benefit is reduced travel time, which increases productivity. Batch picking is often used when typical orders contain only a few items (fewer than four) of relatively small size. Like zone picking, it uses a single planning window per shift.

4. Cluster Picking

Cluster picking involves picking multiple orders simultaneously. Typically, a picker moves through the warehouse with a cart containing several bins, each representing one order. There are two main setups where this method is effective:

1. Cart-based picking with multiple bins — the operator moves through the warehouse and sorts items into orders, reducing unnecessary movement.
2. Automated systems such as vertical lift modules (VLM) or conveyor-based picking zones — the picker places bins in position, triggering automated sorting of items into bins. This approach optimizes batch efficiency by reducing cycle time.

5. Wave Picking

This method is similar to single-order picking, with the key difference being the use of a planning window. In wave picking, orders are scheduled to be picked at specific times during the day — usually to coordinate and optimize shipping operations.

6. Zone-Batch Picking

This hybrid method combines zone and batch picking. Pickers are assigned to specific zones where they also pick in batches. Since both parent methods use planning windows, zone-batch picking does as well.

7. Zone-Wave Picking

Each picker is assigned to a specific zone, where they pick all orders within that area. During each planning window, the picker completes only one order per shift.

Each picker has an assigned zone and completes one order per planning window during the shift.

8. Zone-Batch-Wave Picking

This is the most complex combination of all picking methods. Each picker is assigned a zone and picks all SKUs for multiple orders within it. The picker handles more than one SKU during several planning windows per shift.

Approximate picking performance per hour per picker: unloading a full truck, sorting onto pallets

Picking TypeUnits PickedUnloading full truckload, pallet sorting120 boxesStacking full pallet onto moving conveyor640 boxesPlacing full pallet into pallet rack position32 palletsPicking from flow rack into bags (using pick list)184 order linesPicking from flow rack with light-guided system260 order linesPicking from horizontal conveyors (about 3 items per group, light indication) into bags300 order linesStacking full crates using forklift from floor-level racks29 cratesStacking full crates using powered truck from all rack levels134 cratesStacking crates from mobile pallet rack to powered conveyor (pick list)525 cratesStacking crates from mobile pallet rack to powered conveyor (voice recognition)600 order linesMoving full pallets using counterbalanced forklift from floor area50 palletsMoving full pallets using counterbalanced forklift from rack65 pallets