Warehousing Operations Guide: Part 5

(5-D). Order Picking Types

Quick recap: In our previous articles, we learned about the different kinds of:

? Picking Technologies

? Picking Processes (aka picking methods)

? Picking Systems

This article is divided into different parts.

For Part 1 — Click?HERE.

For Part 2 — Click?HERE.

For Part 3 — Click?HERE.

For Part 4 — Click?HERE.

For Part 6 — Click?HERE.

For Part 7 — Click?HERE.

Now, we will learn about the different picking types.

This includes:

(1) — Pick by Piece (Piece Picking)

(2) — Pick by Case (Case Picking)

(3) — Pick by Pallet (Pallet Picking)

Each of these picking types can be using the various picking processes we discussed earlier in this series.

This can include:

→ Single Order Picking

→ Batch Picking or Multi-Batch picking

→ Cluster Picking

→ Zone Picking

→ Wave Picking

→ Advanced Systems Picking

1) Pick-by Piece

This is also known as Piece Picking / Broken Case Picking). Individual order items are picked, then they are placed on a cart/trolley.

Then the pickers put these items into shipping containers (could be totes, cartons, boxes, or plastic satchels), then they pack them.

After they're packed, labels are printed & put on the shipping containers.

Pickers pick one order at a time throughout the day, by going to each location to pick items on the order list (sales orders).

This is a labour-intensive task. For most businesses, it accounts anywhere from 40-65% of their warehousing operation costs.

Items are mostly stored in fixed locations on static shelves/racks.

Some inventories are stored in temporary or dynamic locations as they have no set place in the warehouse storage system for a variety of reasons.

This is used by many small to medium-sized businesses that have larger SKUs (items) but have fewer pick quantities per pick (usually anywhere from 1 – 15).

SKU stands for stock keeping unit.

While this works well for businesses that deal with smaller order quantities per day, it can become problematic once the quantities or volume of orders grows.

You would see this in companies going through a stage of growth due to an increase in their sale orders or business.

2) Pick by Case (Case Picking)

In this type of picking, items are picked in full cases (cartons) quantities.

Depending on the setup of the warehouse and distribution centre, these cases (cartons) can be picked by the pickers from different storage locations.

This can include:

● Static Shelves on racking (storage locations) which can be fixed or dynamic

e.g., Aisle A, Bay 07

● Carton flow racking

From the pallets stored on the ground (these can be fast-moving products)

● Conveyors

● Automatic storage systems etc

How are products picked?

1. ? Slow-moving products are picked from Static Racking Shelves

2. ? Slow to medium moving products can be picked from carton flow racking

e.g., First-in first-out (FIFO) products such as food items etc.

3. ? Fast-moving products are picked from conveyors, automatic storage systems and pallet positions.

These could be on the ground or on any racking shelves in your warehouse.

As this kind of picking requires a lot of space, the warehouse must be optimised to make the most of this picking type.

This can be done using a variety of automation tools that can help drive the efficiency and productivity of the warehouse/DC.

3) Pick by Pallet (Pallet Picking)

This is the last piece in the order picking series.

In this type of picking, full pallets are picked by pickers that contain a single SKU. That is one order type.

e.g., tissue papers by brand XYZ on a pallet.

When picking from low-level racking locations (aisles), the following types of equipment are used:

? Trolleys

? Pallet jacks

? Low-level order pickers (LLOP)

When picking from higher levels locations such as bay 4, 6, 10 or higher, the following types of equipment are used:

? Turret trucks

? Narrow aisle forklifts

? High reach

? Order picker forklifts

High consumption products are stored on the ground and lower levels. Medium and slow-moving products are stored on higher levels e.g., bay 3, 4, 5, 7, 8 etc.

This is to reduce labour and save time.

Fast-moving products typically have two pallets of each item (SKU) in picking locations to avoid the empty stock.

?? This means pickers can pick without having to wait for replenishment.

Products like paper towels, toilet rolls, coffee cups etc are usually handled in full pallets.

This marks the end of the order picking series.

In the series, we learned about the different kinds of:

• Picking Technologies
• Picking Processes (Picking Methods)
• Picking Systems
• Picking Types

Businesses need to do their due diligence and research before implementing any kind of picking to ensure:

• They are using the right kind of picking technologies.
• Have the right types of equipment for different jobs in the warehouse.
• Have the right kind of warehouse set up i.e., Warehouse design and layout.

This will help in increasing productivity, maximising efficiency, optimising overall operational costs, increasing the safety and wellbeing of the staff (employees).

This article is divided into different parts.

This article is divided into different parts.

For Part 1 — Click?HERE.

For Part 2 — Click?HERE.

For Part 3 — Click?HERE.

For Part 4 — Click?HERE.

For Part 6 — Click?HERE.

For Part 7 — Click?HERE.

Published on 15/11/2021

Last Updated: 02/12/2021 at 12:49 AM