When/why should a warehouse operation use batch picking for order fulfillment?

The modern warehouse is faced with many complex problems that simply must be solved to maximize pick times, minimize mistakes, and create profit. Amongst the most important and high-level choices that must be made is what picking protocol you should utilize. In this day and age, there are multiple proven picking techniques running from batch to wave to cluster. 

While we could drone on about all of these topics for days, we are going to focus on batch picking and how it can help your company fulfill orders faster and more effectively than ever before. When talking about batch picking it is important that we start with how it works before moving on to why it is effective and in what situations it is best utilized. 

What is batch picking? 

Also referred to as batching and multi-order picking, batch picking is a picking protocol that involves warehouse workers picking the same SKUs for multiple orders all at once and taking them to a sorting area for final organization.

The following example will make this process clear: 

• Order 1: 3 widgets, 2 doodads, 12 clips

• Order 2: 5 doodads, 3 clips 

When approached from a batch picking protocol, a warehouse employee will combine the two orders and pick 3 widgets, 7 doodads, and 15 clips in one movement before taking them all to the final sorting area. In the sorting area, they will then be organized into the proper 2 orders before being packaged and finally shipped to happy customers.

To further break down the process it can also be beneficial to look into the workflow of batch picking from start to finish. First, a picking list will be created either manually or by a warehouse management system or order management system. Next, orders will be grouped together based on the location of the products and the size of the orders. Third, the orders will be assigned to pickers and the orders will then be picked. Finally, the pickers will take their cart or tote to the order fulfillment area to be shipped out. 

Why does batch picking work? 

Batch picking offers many unique advantages when compared to similar picking protocols including but not limited to; conserving energy, saving time, and maximizing output. By grabbing multiple small items from one area, pickers are able to fulfill multiple orders in one go. This prevents employees from revisiting the same location twice, enabling you to completely optimize your picking routes to minimize pick times and maximize productivity. 

Batch picking is also only getting easier to optimize with modern WMS And OMS systems that can organize picking routes in a split second no matter how many orders you are saddled with on a daily basis.

When should you use batch picking?

Now that we have covered what back picking is and how it can speed things up, it is time to get into the nitty-gritty, should you use batch picking in your warehouse? 

Batch picking is almost always the best option in smaller warehouses, though it can also offer benefits to larger warehouses depending on workflow and organization. Smaller warehouses thrive in a batch picking system because employees have less walking to do, you can optimize routes to avoid crowding at picking stations, and there is less of a need for large machinery like conveyors and tilt-tray sorters. 

While batch picking has obvious positives in smaller warehouses, it can also be utilized effectively in larger warehouses as well. In larger warehouses, batch picking protocol will become an advantage when there are high concentrations of SKUs or if you are already using picking carts instead of conveyors. Additionally, batch picking can be used extremely effectively when combined with AI intelligence in larger warehouses. 

A modern picking algorithm will consider priority, pick location, travel cost, and other variables to create effective batches of work that will allow teams of employees to fulfill more orders in less time than ever before. Statistically, distribution centers implementing batch picking with the assistance of a modern picking algorithm reduce employee travel time by up to 70%, double picking productivity, and as a result, cut labor hours in half. 

Regardless of the size of your warehouse, batch picking can clearly provide your warehouse with an advantage. Whether you have 5 employees covering a small warehouse or a team of 100 fulfilling orders around the clock, batch picking will allow you and your team to maximize output while minimizing effort and labor hours. 

While batch picking has ample positives for just about any warehouse, it is important to acknowledge when batch picking may not be the most effective protocol. Batch picking may not be the most effective when orders feature a low quantity of SKUs and being forced to organize the orders after picking can make batch picking a poor option depending on the business.

Is batch picking right for you? 

Now that you have learned about the pros and cons of batch picking it is important to look at the size of your warehouse, orders, and team to determine how you can maximize fulfillment. Additionally, it is extremely important to look at your WMS, OMS, and physical technologies to see how you can optimize your picking. It is also important to look at potential growth within your distribution center and how that may affect team size, warehouse size, and what new technologies you may need going forward. 

Processing all of that information can be a bit of a nightmare, luckily, here at World Class Integration, we specialize in answering any questions you have during any stage in your distribution center's growth. We have the tools you need to streamline your warehouse processes by offering consultation on your system and layout design and then providing the equipment you need to fully utilize it. If you think batch picking may be for you, or you want to maximize your productivity, give us a call.