When it comes to fulfillment, time is money—literally. The longer your warehouse spends on picking and packing orders, the less profit you see.
Enter: batch picking.
This tried-and-true method isn’t just about speeding up your operations—it’s about maximizing efficiency, reducing errors, and boosting your bottom line.
In this post, we’ll explain batch picking, its benefits, and best practices so you can decide if it’s right for your business.
We also spoke with Rob Rickerson, director of operations and analytics at Red Stag Fulfillment, to get his expert tips on who should use batch picking and how to make the most out of this strategy.
What is batch picking?
Batch picking, also called multi-order picking, is a warehouse order fulfillment method that involves retrieving inventory for multiple customer orders at once. Unlike the traditional method, which requires completing one order at a time, batch picking allows a picker to handle multiple orders in a single trip.
As Rickerson says:
“It’s a one-to-many relationship in terms of SKUs to orders. The benefit is heightened efficiency. If you have an instance where one SKU is picked for 100 orders, you go to the location one time and pick 100 items, which satisfies the requirement. Picking efficiency comes through as a reduction in travel distance and a reduction in touches.”
– Rob Rickerson
Who should use the batch picking method?
Multi-order picking is critical in industries like e-commerce, retail, and manufacturing, where quick and accurate fulfillment is key to staying ahead of the competition.
But it can work well for any high-volume business with similar items.
Rickerson noted that batch picking is particularly helpful “in situations where you have common items or common order types that have high order volumes throughout the day.”
How batch picking works
A smooth batch picking process depends on the right tools and technology.
- Order management system (OMS):
An essential software tool that analyzes and groups orders based on common items or storage locations. The OMS intelligently consolidates orders to maximize picking efficiency. - Warehouse management system (WMS):
Integrates seamlessly with the OMS to optimize pick paths, reducing travel time and increasing productivity. The WMS guides pickers through the most efficient route to collect all items for the batch. - Pick lists:
Generated by the WMS, these consolidated lists provide pickers with a clear overview of all items needed for the batch of orders. Pick lists are designed to minimize confusion and enhance accuracy. - Carts or totes:
Used to collect and separate items for different orders within the batch. These containers help maintain order integrity and prevent the mixing of products between orders.
Here’s a quick overview of the batch picking process:
- Order grouping:
The batch picking process starts by grouping multiple orders that share common items or storage locations. An OMS can automatically group batchable orders that contain the same items and quantities and create pick lists. - Route optimization:
Next, your WMS will calculate the most efficient route. This step ensures the picker spends the least amount of time moving from one location to another, hitting all the necessary spots in a single, streamlined trip. - Picking process:
With the optimized route in hand, the picker moves through the warehouse, collecting all the items for the batch of orders. By consolidating orders, the picker significantly reduces travel time and boosts productivity. - Order sorting:
Once the picker returns with the batch, the items are sorted and allocated to their respective orders. Depending on the warehouse’s setup, this can be done manually or through automated systems. - Packing and shipping:
Finally, the sorted orders are packed and prepared for shipping much faster than they would be with traditional picking methods.
Benefits of batch picking
Let’s examine the biggest benefits of batch picking:
Reduced picking time
Batch picking dramatically speeds up the picking process by grouping multiple orders with common items or storage locations. This approach reduces time spent navigating the warehouse, resulting in faster order fulfillment.
Increased productivity
The average warehouse worker spends 80% of their shift walking. The time savings from batch picking boost productivity, allowing pickers to fulfill more orders in less time. This is especially valuable during peak seasons when high order volumes demand quick turnaround, helping you meet customer needs more effectively.
Cost savings
Batch picking leads to significant labor cost savings by enabling pickers to handle more orders with fewer workers. Fewer trips around the warehouse also reduce wear and tear on equipment, lowering maintenance costs and extending the lifespan of carts and forklifts.
Accuracy and error reduction
Batch picking minimizes picking errors by consolidating orders with common items or locations, reducing the chances of selecting the wrong item. This improved accuracy leads to fewer returns and exchanges, enhancing customer satisfaction and streamlining the supply chain.
Batch picking versus other picking methods
Still not sure batch picking is right for you? Let’s see how it stacks up against other popular picking methods.
Single order picking (discrete picking)
Single order picking is best for small operations or low order volumes. This involves sending someone to gather the products for a single order and then having them come back to the packing area with only those products.
- Easy to implement but less efficient due to high travel time per order
- Offers high accuracy and flexibility
Zone picking
Zone picking is ideal for large warehouses with diverse product ranges and high order volumes, but unlike batch picking, it doesn’t require the same items to be ordered.
- Reduces travel time by assigning pickers to specific zones.
- Requires careful coordination and management to avoid bottlenecks.
Wave picking
Wave picking combines elements of batch and zone picking.
- Groups orders into waves based on factors like shipping schedules or priorities.
- Offers a balance between efficiency and specialization but requires complex setup.
Cluster picking
Cluster picking involves collecting multiple orders simultaneously using separate bins or totes for each order.
- Often confused with batch picking.
- Optimizing cluster picking for your warehouse operations requires careful planning to ensure accuracy and efficiency.
Choosing the right picking method depends on factors such as warehouse size, storage location, order volume, product diversity, and available resources.
While batch picking excels in efficiency and cost savings, it may not be the best fit for every situation. Consider your unique needs and goals when selecting a picking method for your warehouse.
Questions to ask before implementing batch picking
Sold on batch picking? Rickerson advises asking the following questions to determine if it’s the right method for you.
- Does the need for batch picking processes exist in your warehouse?
- What’s the size of your warehouse or distribution center? If it’s small, you won’t save any time with batch picking.
- What kind of labor resources do you have? Do you have enough staff for picking, packing, and support for other processes?
- What’s the data from your warehouse management systems telling you? Are your orders made up of enough of the same items to make batch picking worth it?
- Do orders frequently come in at the same time so you can batch them? If they’re too spread out, it won’t work.
- Can your warehouse management software handle downstream consolidation or aggregation (two critical capabilities)?
If these criteria aren’t in place, you might not see the same gains from batch picking as you would from another order fulfillment process.
Implementing batch picking in your warehouse
When gearing up for batch picking, start by evaluating your current processes and spotting potential hurdles—like technology upgrades or staff training needs. Setting clear goals will help facilitate a smooth and successful transition.
Initial assessment and planning
- Ask yourself if batch picking is the right approach for your situation. Rickerson says that adding complexity by choosing the wrong picking method can be a net negative for your operation.
- Analyze your current processes, identify inefficiencies, and set clear goals for improvement.
- Determine the necessary changes to your warehouse layout, technology, and workforce.
- Establish key performance indicators (KPIs) to measure the success of your implementation, such as picking accuracy, average picking time, and labor costs.
Technology and tools
- Invest in a robust WMS that can handle batch picking requirements and integrate with other systems.
- Consider automation solutions like automated guided vehicles (AGVs), conveyor systems, or robotic pickers to enhance efficiency and reduce manual labor.
- Provide comprehensive training so your staff can effectively use the new technologies and processes.
Workforce management
- Develop training programs covering technical aspects and practical skills for efficient batch picking.
- Implement effective workforce management strategies, such as scheduling pickers based on order volumes and providing ongoing support.
- Foster a culture of communication and collaboration to address issues promptly.
Best practices for effective batch picking
Want to get the most out of your batch picking and inventory management? Follow these best practices so your process runs as smoothly and effectively as possible.
Set up your warehouse for success
- Organize your warehouse to reduce travel time and increase picking efficiency.
- Place high-frequency items in easily accessible locations and place items often ordered together near each other.
- Use vertical space effectively with appropriate shelving and storage solutions.
Focus on creating an optimal pick path
- Design efficient pick paths to minimize travel time and congestion.
- Implement one-way pick paths to reduce traffic and prevent bottlenecks.
- Regularly review and adjust pick paths based on changes in order patterns and warehouse layout.
Track progress and identify areas of improvement
- Review KPI performance to identify strengths and weaknesses.
- Conduct regular process reviews to identify areas for improvement and gather staff feedback.
- Provide ongoing training and support, so your team stays aligned with best practices and industry standards.
Work with Red Stag Fulfillment
Implementing batch picking can significantly enhance warehouse efficiency, reduce costs, and improve order accuracy. At Red Stag Fulfillment, we have deep experience with many picking methods–including batch picking–and can provide expert advice to help guide you.
As Rob says:
“One size does not fit all. You have to deploy the right pick method at the right time, both based on product mix, physical size, volume, and level of technology advancement. Misapplied, they can do more harm than good. You have to be strategic about leveraging the right method at the right time.”
– Rob Rickerson
Get in touch with us today to learn how we can help you choose the best order picking strategy for your business.
