If you’ve never changed your order picking method, this article is definitely a must-read. We’ll explain the five most popular order picking methods – plus a new contender – so you can decide which one is best for your operation.

For those who are 100% certain they're using the optimal order picking strategy, check out our article about How to Improve Order Picking Speed and Accuracy.

How to Choose the Best Order Picking Strategy

Discrete Picking

Also known as single order picking, discrete picking is the most common order picking method. The associate simply walks around the warehouse picking one item at a time. 

• PROS: Orders aren’t co-mingled, so accuracy is higher
• CONS: It's one of the least efficient picking methods because of all the walking
• BEST FOR: Operations with a limited number of SKUs that receive a lot of small orders
• WORST FOR: Large facilities and/or operations that receive a high volume of orders

Batch Picking

With batch picking, one associate brings cases of different products to a packing station and assembles multiple orders at once. Larger facilities may utilize wave packing, which is a form of batch picking. 

• PROS: Reduced time spent walking around improves efficiency
• CONS: Higher potential for error, can be offset with barcode scanners or other solutions
• BEST FOR: High-volume operations with a small number of SKUs
• WORST FOR: Large facilities and operations with a high number of SKUs

Wave Picking

The main difference between batch and wave picking is the number of associates involved in each batch. With wave picking, multiple associates bring cases to the packing station from different parts of the facility. Orders are grouped together in waves to ensure timely processing in a large facility.

• PROS: High efficiency, minimizes walking around
• CONS: Potential for error remains, can be offset with barcode scanners or other solutions
• BEST FOR: High-volume operations with a high number of SKUs
• WORST FOR: Small facilities or operations with small orders

Cluster Picking

This method is a combination of discrete picking and batch picking. When cluster picking, an associate pushes a cart through the facility picking up products for multiple orders. 

• PROS: More efficient than discrete picking
• CONS: Still requires a lot of walking, errors still possible without assistance from barcode scanners or other technology
• BEST FOR: Small to medium-sized facilities with small to medium-sized SKUs
• WORST FOR: Big facilities and operations with large products

Zone Picking

Also known as “pick and pass,” zone picking is a combination of cluster and wave picking (kind of sort of). Like wave picking, associates stay in a designated area. They also push a cart around and gather products for multiple orders at a time, similar to cluster picking.

What’s different about zone picking is that the cart gets passed from one associate to another. For example, let’s say your facility handles apparel. The WMS identifies multiple orders that require men’s athletic socks, undershirts and/or underwear. The first picker, based in the sock section, picks all the socks. Then, they pass the cart to their coworker in the men’s undershirt section. That associate adds all the undershirts, then delivers the cart to the person in the underwear section. The underwear picker completes the order and takes the cart to a packing station. Meanwhile, the sock and undershirt workers continue to fill other orders.

• PROS: Associates know their area and pick faster, less walking than cluster picking
• CONS: More labor intensive, errors still possible without assistance from barcode scanners or other technology
• BEST FOR: High-volume operations with many small to medium-sized SKUs
• WORST FOR: Operations with large products, a WMS that doesn’t support zone picking

NEW! Robot-Assisted Picking

Automated Mobile Robots (AMRs) are an effective way to improve order picking accuracy and speed. If you’ve looked into robots in the past and decided they weren’t a good fit, take a moment to watch the video below.

Associates no longer have to follow slow-moving carts, the robots bring orders to your workers (kind of like zone picking). They can also bring items for put-away. Locus Robotics has a variety of models so you can use your existing containers and shipping cartons. 

• PROS: Significantly improves productivity and accuracy, no upfront costs for robots
• CONS: Requires software investment and WMS system*
• BEST FOR: High volume, indoor operations
• WORST FOR: Outdoor operations, facilities that handle very large items

* Contact us for a free ROI estimate

Request a Free Warehouse Optimization Audit

Whether you have a single building, an outdoor facility or a multi-location operation, we can help you find ways to save money and improve productivity. We can help you choose the best picking strategy, optimize picking routes and decide if robots are right for you.

Let us know what problems you’re trying to solve or what goals you’d like to achieve. We’ll provide solutions in a zero-pressure free consultation. 

To take advantage of our offer, contact us online, by phone at (800) 226-2345 or in person at one of our eleven locations throughout Georgia and Florida

GEORGIA: Albany, Macon, Midland, Valdosta
FLORIDA: Jacksonville (2 locations), Ocala, Orlando, Lakeland, Tampa, Winter Haven

Further Reading
How to Improve Order Picking Speed and Accuracy
Need More Warehouse Space? Don’t Move. Do This First
Take the Guesswork out of Material Handling

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