Order picking simply explained

Order picking in logistics refers to the process of assembling and packing goods according to specific customer orders. It is critical to the efficiency and accuracy of the supply chain as it ensures that the right products are shipped to the customer in the right quantity and quality.

Well-organized order picking improves customer satisfaction and reduces errors, time and costs. Modern technologies such as barcode scanners and automated systems help to optimize this process.

The order picking process runs through the following process steps:

1. The order is received: First, an order is entered manually or automatically. Alternatively, this is done via an e-commerce system.
2. Compilation of the order: The items are now selected, with the underlying order serving as the basis for this.
3. Identification of articles: Barcodes, RFID tags or article numbers are used to identify the required items.
4. Item removal: In the next step, the pickers remove the required items from shelves or containers in the warehouse logistics system. Typically, picking techniques such as forklift picking, pick-by-light or voice picking are used for this.
5. Quantity check: Once the items have been picked, the quantity is compared with the order.
6. Packing: The order is now packed in compliance with the packing instructions.
7. Quality control: Before the picked goods are dispatched, they are subjected to quality control.
8. Dispatch: In the final step, the shipment is dispatched or alternatively stored in the warehouse for further processing later.

Manual order picking

With manual order picking, trained employees take over the entire picking process.

Benefits:

• Individual response to individual orders
• Teamwork possible

Disadvantages: Prone to errors

• Prone to errors
• Dependence on the presence of the responsible persons

Automated order picking

In automated order picking, picking robots handle individual boxes or even warehouses.

Benefits:

• More efficient and effective warehouse work
• Ongoing costs can be reduced

Disadvantages:

• Downtime in the event of robot failure
• Usually relatively complex installation and integration into warehouse or system landscape

Single-stage order picking (order-oriented)

In single-stage order picking, an order is picked directly in the warehouse or in production. The employee responsible goes to the storage location, picks up the goods and places them in the container provided.

Benefits:

• Uncomplicated process for which no special picking system is required
• Storage zones are simply divided up
• Fast order picking of individual customer orders

Disadvantages:

• Customer orders are not put together optimally
• Long distances may be involved
• Series-oriented processing is not possible

Order-oriented serial order picking

Order-oriented serial picking is the simplest picking method. Here, the order picker processes all orders in chronological order one after the other. Storage zones can be passed through.

Benefits:

• Simple familiarization
• Responsibilities are quickly defined
• Little organizational effort

Disadvantages:

• Long throughput times for orders
• Long picking routes
• Time-consuming order handover at the storage zone to the next responsible picker

Order-oriented parallel order picking

With order-oriented parallel order picking, the order also consists of several items from different zones in the warehouse. This method is used in particular for split orders. Once the partial orders have been completed, they are merged into the overall order.

Benefits:

• Picking zones are split into small areas
• Shorter distances and throughput times

Disadvantages:

• The partial orders must be reunited at a consolidation point

Two-stage order picking

Two-stage order picking is also known as series-oriented parallel order picking and is usually used when several individual items of a product are to be processed.

Benefits:

• The picker only has to approach the storage location once

Disadvantages:

• Preparation and consolidation of orders is very time-consuming

Multi-level order picking

With multi-level order picking, several customer orders are processed in parallel at once. Depending on the warehouse type and zones, the orders are cumulated first. They are then distributed to the orders at the packing station.

Benefits:

• Picker can remove numerous items from a storage compartment at the same time.

Disadvantages:

• Large quantities have to be counted manually, which is time-consuming and error-prone.

Batch order picking

Batch order picking processes picking orders according to a planned principle. The necessary items are put together in a "batch", i.e. item-only batches, and then processed.

Benefits:

• Greater efficiency as processing is combined
• Fewer routes

Disadvantages:

• Time-consuming, as all orders are initially collected in batches
• Less flexibility, as different orders have to be created individually

Static order picking

With static picking, the person responsible moves to the individual storage location. The item is picked here on site. It is also known as man-to-goods order picking.

Dynamic order picking

In dynamic order picking, the warehouse management system automatically retrieves the storage unit and moves it to the picking point, where the required quantity is picked. The load carrier is then automatically stored again. Goods-to-man.

Pick-by-voice

Pick-by-voice systems use voice-activated instructions that are relayed to employees via headsets, enabling hands-free working and reducing errors.

Benefits:

• Hands-free working: Employees can use both hands freely, improving efficiency and ergonomics.
• Flexibility: Can be used in a variety of warehouse environments, including those where visual aids may interfere.

Disadvantages:

• Initial investment: High cost of purchasing and implementing systems.
• Dependence on language: Strong accents or language barriers can impair effectiveness.

Pick-by-light systems

Pick-by-light systems use visual signals to indicate the correct picking location to employees, which supports fast and error-free order picking. Both systems increase efficiency and accuracy in warehousing.

Benefits:

• Visual guidance: illuminated displays at storage locations enable fast and intuitive picking, which increases picking speed.
• High accuracy: Visual support reduces errors and increases the accuracy of picks.

Disadvantages:

• Cost: High initial costs for installing the illuminated systems and integrating them into the warehouse management system.
• Limited flexibility: Less suitable for dynamic storage environments where storage locations change frequently.

Automated storage systems (AS/RS)

Automated storage systems (AS/RS) use computer-controlled machines to automatically store and retrieve goods, enabling optimal space utilization and high efficiency. These systems are ideal for warehouses with high throughput and limited space and improve inventory accuracy through real-time data collection. They reduce manual intervention and increase safety by minimizing accidents at work.

Barcode and RFID technology

Barcode and RFID technologies are used in order picking for fast and error-free data capture. Barcodes are scanned to store information in a warehouse management system, while RFID tags can be read wirelessly and without line of sight. Both technologies improve inventory accuracy and reduce manual input errors, increasing efficiency in warehouse operations.

The following tips can make order picking much easier for companies:

• Good warehouse organization and warehouse logistics for easy retrieval and overview
• Use of a suitable picking system
• Optimization of walkways
• Train order pickers in detail
• Keeping an eye on key performance indicators such as speed and error rate and reacting if necessary
• Establish reliable quality mechanisms
• Use technologies and robots
• Continuously improve existing processes
• Safe conditions, for example through safety equipment and a suitable workplace

• Batch traceability: With Yaveon 365, you enjoy absolute security thanks to the complete traceability of your batches. Ensure that the right batches are always picked, minimize errors and meet the highest quality standards.
• Mobile picking: Experience a new dimension of efficiency with mobile order picking. Yaveon 365 enables your warehouse teams to receive and process orders in real time - for significantly higher productivity and shorter processing times.
• Quality control: Rely on the highest product quality through integrated quality checks. Only approved and tested batches are picked, ensuring the quality of your products and minimizing the risk of recalls.
• Priority-controlled order picking: Optimize your stock levels with intelligent priority control. Yaveon 365 takes into account receipt or expiration dates (FEFO) as well as container breakage so that lower priority stocks are used first - for efficient and transparent warehouse management.