Wave picking is a strategic approach to order fulfillment that’s gaining traction in modern warehouses. This method organizes orders into groups—or “waves”—to optimize the picking process.
Compared to other picking methods, it can help…
- Reduce warehouse travel.
- Speed up order processing.
- Get your shipments out on time, every time.
Whether you’re curious about improving your current system or exploring new fulfillment strategies, our comprehensive guide to wave picking will walk you through its concepts, benefits, and best practices.
What is wave picking?
Wave picking is a warehouse order fulfillment method where orders are grouped and processed in batches or “waves” to optimize picking efficiency.
Instead of picking items for each order individually, wave picking organizes multiple orders based on common criteria, such as product type, shipping method, or delivery schedules.
Rickerson explains:
For example, you might group all orders that need to be shipped by a specific carrier, or all orders that need to be out the door by 5 pm. The specific criteria used to create these waves depend on what works best for your particular warehouse setup and fulfillment needs.
This approach allows warehouses to streamline their operations by tackling similar tasks together, rather than constantly switching between different types of work.
It’s a strategic way to manage the flow of work on the warehouse floor that minimizes unnecessary back-and-forth travel, making it especially helpful in fast-paced environments like ecommerce fulfillment centers.
Wave picking vs. other picking methods
Wave picking isn’t the only method you can use. Discrete, cluster, zone, and batch picking are also options, each with its own unique benefits.
| Picking Method |
Description | Pros | Cons |
|---|---|---|---|
| Wave Picking | Picking items for multiple orders in waves. | Efficient for high volume, can be automated | Potential congestion, longer fulfillment times |
| Zone Picking | Workers pick items within designated zones. | Reduced travel time, specialized expertise | Initial setup complexity, coordination challenges |
| Single Order Picking | Workers pick items for one order at a time. | Simple process, easy to manage | High travel time, inefficient for large warehouses |
| Batch Picking | Workers collect items for multiple orders and sort later. | Reduced travel time, efficient for similar items | Sorting complexity, potential for errors |
| Cluster Picking | Workers pick and sort items using multi-bin carts. | Eliminates separate sorting, reduced errors | Lower item volume, more complex picking process |
How wave picking works
With wave picking, you don’t pick orders immediately as they come in. Instead, you use a warehouse management system (WMS) to group orders into waves.
Here’s a closer look at how it works:
- Orders are grouped based on various factors like delivery deadlines, shipping methods, or product categories. This guarantees that items needing to be shipped together are picked together, streamlining the packing and shipping processes.
- Waves are scheduled at specific daily intervals, aligning with shipping schedules or workload distribution needs. This can be tailored to peak or slower periods to maintain a balanced workflow.
For example, Rickerson recommends scheduling wave picking around carrier pickups.
You can also optimize shift schedules with wave picking, as Rickerson explains:
Benefits of wave picking
While there are many benefits to this order picking method, we covered the most impactful ones below.
Increased efficiency
One of the main advantages of wave picking is minimizing picker travel time. By clustering orders and optimizing routes, pickers spend less time walking and more time picking, leading to faster processing and increased productivity.
As Rickerson says:
“The critical benefit of wave picking is applying labor to the right thing at the right time. In the world of same-day shipping as a fulfillment provider, the last thing you want to do is get the work done at the wrong time. There’s a downstream impact if you miss a carrier cutoff or overload one shift and underload another.”
Scalability and flexibility
Whether dealing with seasonal spikes or daily fluctuations in order volumes, you can adjust waves accordingly.
Dynamic wave picking, in particular, allows for real-time adjustments based on current demands, ensuring the warehouse operates efficiently even during peak times. (More on what dynamic wave picking is in a bit.)
As your business grows, the volume and complexity of orders will increase. Wave picking scales to meet these demands. By refining and expanding your picking strategy, you can handle larger volumes without compromising efficiency or accuracy.
Improved accuracy
By focusing on smaller, manageable groups of orders, pickers can maintain higher concentration levels, reducing the likelihood of errors. This precision is particularly important for warehouses dealing with high-value or perishable goods, as errors with these goods can result in costly financial losses or even safety risks.
Wave picking methods
There are a few wave picking methods you can use. Many strategies incorporate multiple wave methods, so don’t feel constrained to just one of these.
Single-order wave picking
- Involves picking items for one order at a time within each wave.
- Ideal for smaller operations or when dealing with high-value or fragile items that require careful handling.
- Minimizes the risk of errors, making it suitable for scenarios where accuracy is more critical than speed.
Multi-order wave picking
- Multiple orders are picked simultaneously within a single wave.
- Enhances efficiency by allowing pickers to collect items for multiple orders in one pass through the warehouse.
- Beneficial for high-volume operations where speed is essential, reducing the overall picking time and increasing throughput.
Zone-based wave picking
- Divides the warehouse into different zones, with each picker assigned to a specific zone.
- Orders are split into segments corresponding to these zones, and items are picked independently within each zone before being consolidated.
- Reduces picker travel time and congestion, making it ideal for large warehouses with diverse inventory.
It’s also crucial to consider dynamic versus fixed picking.
- Dynamic wave picking: Waves are adjusted in real time based on current order volume and priority. It offers flexibility and responsiveness, allowing warehouses to adapt quickly to changes in demand or unexpected order spikes.
- Fixed wave picking: Waves are scheduled at fixed times and follow a set pattern. Fixed wave picking provides predictability and structure but lacks the flexibility of dynamic wave picking.
Essential wave picking tools and tech
To succeed with wave picking, you need the right tools.
Warehouse management system
A WMS is integral to managing your warehouse operations. It groups orders, schedules waves, and directs pickers through optimized routes. It also tracks inventory in real-time, helping keep stock levels accurate and order accuracy high.
Other warehouse technologies
You should further optimize wave picking by integrating your WMS with other technologies, such as barcode scanners, radio frequency identification (RFID) systems, and automated storage and retrieval systems (AS/RS).
These tools provide additional layers of efficiency, accuracy, and speed to the picking process.
Implementing wave picking in your warehouse
Before implementing wave picking, thorough planning is essential.
- Assess warehouse layout and design: Evaluate your current warehouse layout so it supports efficient waves. This includes analyzing the arrangement of storage areas, picking zones, and pathways to minimize travel time and reduce congestion.
- Evaluate current order fulfillment processes: Review your existing order fulfillment processes to identify bottlenecks and inefficiencies. Understanding your current operations will help tailor your wave picking strategy to your needs and challenges.
- Select the right wave strategy: Choose the strategy that best fits your warehouse operations. Consider factors such as order volume, product variety, and the physical layout of your warehouse.
- Train staff and transition: Train your staff on the new wave picking procedures and any new technology. Gradually transition to the new system and address any issues promptly.
3 wave picking best practices
To get the most out of your wave picking system, follow these best practices:
1. Measure order volume
Wave picking is most effective when you have a steady stream of orders that can be grouped efficiently. Regularly analyze order data to ensure you have enough volume to justify this method.
If order volumes are low, consider consolidating waves or adjusting schedules to maintain efficiency.
2. Organize wave picking effectively
Organizing waves based on specific criteria can greatly enhance efficiency and reduce picking times.
Here are a few effective organizational strategies:
- Group orders according to shipping schedules. For example, you might prioritize orders with the same shipping deadlines or those that need to be dispatched at similar times. This enables timely processing and dispatch, aligning your picking operations with delivery commitments.
- Organize waves based on shipping carriers. By grouping orders for the same carrier, you streamline the handoff process and reduce the likelihood of sending shipments with the wrong carrier.
- Group orders by product location. This minimizes travel time and allows pickers to move through the warehouse more efficiently, reducing the time spent searching for items.
- Group orders by product similarity. Similar products are often located close together, and products of similar size can be transported using the same methods–smaller items with handheld carts, larger items with pallet jacks or forklifts, etc.
3. Visualize and plan waves
Planning each wave can significantly reduce congestion and enhance overall efficiency.
Use your WMS to plan each wave. By visualizing the picking process and identifying potential bottlenecks, you can allocate resources more effectively and adjust wave schedules to maintain a smooth workflow.
Use charts and diagrams to visualize wave plans. For instance, a Gantt chart can help map wave schedules and identify overlaps or conflicts. Floor plan diagrams can highlight optimal picking routes and zones, making sure pickers follow the most efficient paths.
Here’s what a wave planning chart might look like:
6 wave picking challenges (and solutions)
Wave picking isn’t without its challenges. We’ve detailed the most common ones below, along with solutions.
1. Increased scheduling oversight
One of the primary challenges of wave picking is the need for meticulous scheduling oversight.
Effective picking requires detailed planning and precise timing to execute each wave smoothly. This involves coordinating order release times, aligning with shipping schedules, and managing the availability of pickers.
The complexity of this task can be overwhelming, especially in large-scale operations with high order volumes. Without proper oversight, waves can become disorganized, leading to delays and inefficiencies.
2. Sorting area complexity
Wave picking often results in a high volume of items arriving at the sorting area simultaneously, creating congestion and complexity. Managing picking and packing processes requires robust systems and well-trained staff. Inadequate handling can lead to sorting errors, increased processing times, and customer dissatisfaction.
3. Picking downtime
Between waves, there can be periods where pickers are idle while waiting for the next wave to be released. This downtime can lead to inefficiencies and reduced productivity.
4. Increased lead time
While wave picking can improve efficiency, it can also increase lead time if not managed properly. The time you spend grouping orders into waves, scheduling them, and executing each wave can add to the overall order fulfillment time.
5. Integration with existing systems
Without proper integration into your current systems, the wave picking process can become inefficient and error-prone.
6. Handling different product types and shipping requirements
Diverse product types and varying shipping requirements can complicate things.
Optimize Your Fulfillment with Expert Help
Choosing the right picking strategy is difficult. The right one can significantly boost warehouse efficiency, but the wrong one can actually add to the chaos and increase costs and fulfillment times quite a bit.
As Rickerson says:
At Red Stag Fulfillment, we have over 10 years of experience optimizing picking strategies for businesses of all sizes. Our team can help you determine which picking method is right for your operations and explore how we can help you reduce your fulfillment costs and complexity.
Ready to reduce your fulfillment burdens? Reach out to start a conversation.
