Order fulfillment in modern warehouses requires a balance of speed, precision, and cost-efficiency. One solution that has transformed fulfillment workflows is batch picking, a method where similar orders are grouped and picked in one trip.
Whether you’re managing e-commerce, wholesale, or third-party logistics (3PL) operations, the batch-picking process cuts down on travel time, streamlines operations, and helps warehouses handle high-volume orders easily.
In this guide, we’ll explore what batch picking is, how it works, its key benefits, and the best practices to implement it efficiently
What is Batch Picking?
Batch picking, also called fulfillment batching or multi-order picking, is a method where one employee, a picker, gathers multiple orders at the same time and then sorts them into individual orders.
By consolidating different orders into one picking task, the batch-picking process can increase the number of orders processed per hour, enabling pickers to complete more tasks in less time, especially during peak seasons.
For example, let’s say a driver receives three orders from a restaurant, but all the deliveries are in the same neighborhood. Instead of making separate trips back and forth, the driver picks up all the orders in one go, plans the most efficient route, and drops them off to each customer on time.
Batch picking in a warehouse works the same way. Instead of fulfilling one order at a time, a picker gathers items for many different orders during a single trip through the warehouse. This saves time, reduces unnecessary backtracking, and ensures all orders are fulfilled faster.
How Batch Picking Works: A Step-by-Step Guide
Here’s a step-by-step explanation of how fulfillment batching works:
Step 1: Grouping Orders
Orders are grouped into batches based on shared products and the proximity of those products within the warehouse. For example, if three orders include the same product, they’re consolidated into one picking task.
Step 2: Create a Picking List
After grouping, a picking list is generated with the SKUs (stock-keeping units, or product tracking codes), quantities, and locations within the warehouse, so the picker knows exactly where to go and what to pick for all the orders in the batch.
Step 3: Collecting Items
Guided by mobile scanners that display the best route, pickers move around the warehouse to collect all items for the batch. These are placed into totes (the plastic bins often used for items) or slots on a picker’s cart designated for the items.
Step 4: Sorting into Individual Orders
Once the batch is picked, the picker or the packing team has to sort the items into the individual orders that had been batched. This could involve organizing items manually or using scanners to track each item as it’s placed into a designated bin.
Step 5: Preparing for Shipment
Each order is packed, labeled, and sent for shipping.
Batch picking strategy streamlines the fulfillment workflow by cutting down on trips and saving time. It’s especially useful in busy warehouses handling multiple orders with the same SKUs.
Batch Picking vs. Other Picking Strategies
“There is no best method for all businesses and there may be different picking methods within the same warehouse. You may have case picking at the order level and picking at the unit level in a cluster or pick-and-pass model,” says David Haley, a Director of Operations Consulting at Sharphurst LLC.
There are other picking methods like single-order picking, wave picking, zone picking, and hybrid picking that might cater to your operational needs better. Let’s explore different picking strategies and compare them with batch picking.
Batch Picking vs. Single Order Picking (Discrete Picking)
As the name suggests, single-order picking requires operators to pick SKUs one order at a time. Although its specificity might avoid mix-ups compared to batch picking, it can be time-consuming, especially for big warehouses that receive hundreds of orders of the same items daily.
Single-order picking is best for: Single-order picking works well for small businesses with a compact, single-room inventory. It’s also ideal if you sell only one or two items, making manual handling straightforward and efficient.
Batch Picking vs. Wave Picking
Wave picking combines multiple batches into waves based on criteria like shipping time, order priorities, or zones. Orders are picked in timed waves to align with downstream processes like packing or shipping. Wave picking is built on advanced synchronization to help big warehouses with large numbers of pickers be more efficient.
Wave picking is best for: Wave picking is suitable for warehouses handling high-order volumes by batching orders to meet shipping deadlines or order priority.
Batch Picking vs. Zone Picking
Zone picking divides a warehouse into sections called “zones” and each picker is assigned to a specific area. When orders arrive, the pickers collect items located only in their specific area. This is different from the batch-picking strategy where one picker may have to walk the whole warehouse to complete a batch-picking list.
Although many big warehouses use zone picking to manage orders, they need cloud-based WMS software to balance their workload.
Zone picking is best for: Zone picking is best for warehouses with diverse products stored across different sections because it reduces travel time for pickers.
Batch Picking vs. Cluster Picking
Often confused with batch picking, cluster picking collects items for multiple orders in a single trip but uses designated bins, carts, or containers to sort the items simultaneously as they are picked. In batch picking, pickers collect items for multiple orders in one trip and sort them later, usually at a packing station.
The main difference is when the sorting takes place—batch picking defers it, while cluster picking handles it simultaneously.
Cluster picking is best for: Cluster picking is best suited for warehouses that handle a high volume of small, multi-item orders.
Batch Picking vs. Case Picking
Case picking involves retrieving whole cases or boxes of products from storage locations to fulfill orders. Pickers collect pre-packed cases and send them directly to packing or shipping, with minimal handling of individual items.
Case picking is best for: Case picking is very common in e-commerce fulfillment centers, apparel warehouses, and other warehouses handling consumer goods that ship in cases of the same small product.
Hybrid Picking: Combining Batch, Zone, and Wave Picking
Hybrid picking combines batch, zone, wave, cluster, and case-picking methods to streamline warehouse management. The warehouse is divided into zones with pickers assigned to each section.
Orders with common SKUs in the same zone are grouped together so pickers collect items for multiple orders in one trip. If the orders are from different zones, they are synchronized into waves based on shipping time.
Instead of relying on a single method, hybrid picking adapts according to real-time order management and complexities.
Hybrid picking is best for: Warehouses with complex operations, diverse inventory, and varying order sizes. It suits 3PLs and other warehouses that need maximum flexibility to manage real-time demands, optimize picker efficiency, and streamline processes across multiple zones.
Benefits of Batch Picking
Some ways warehouses benefit from using a batch-picking strategy are:
- Reduced Travel Time: Workers can walk up to 10 miles a day in a warehouse setting. Batch picking minimizes this by organizing picks based on proximity, reducing the need for repeated trips to the same locations.
- Cost Savings: Implementing batch picking can reduce labor costs and mean lower wear and tear on equipment and reduced maintenance costs.
- Accuracy in High-Volume Orders: Big warehouses often receive a high volume of orders. Batching minimizes picking errors by grouping similar items and reduces returns.
Key Challenges in Batch Picking
Although batch picking has its benefits, it still comes with many challenges in real life. These challenges are often a result of the wrong implementation or the wrong selection of the picking method used by the business.
Challenge #1: Managing Product Diversity in Batches
Handling a wide variety of similar products each with its own unique SKU in a single batch can lead to confusion and mispicks if items aren’t well-organized. The complexity increases during peak seasons when high order volumes can overwhelm pickers, resulting in delays and errors.
When items are picked in large batches, sorting them into individual orders can lead to mistakes. Additionally, consolidating items often requires dedicated sorting areas, which can be difficult in warehouses with limited space.
Challenge #2: Worker Training for Order Management
Batch picking demands trained workers who understand optimized routes and sorting techniques. But training each operator individually can be time-confusing and can often delay operations, especially for warehouses with a high volume of orders.
Did you Know: According to the Zebra Warehousing Vision Study, only 75% of warehouses use partial automation to equip workers with devices and tools to fulfill repetitive tasks.
Challenge #3: Real-time Inventory Inaccuracies
Managing orders manually often leads to gaps in knowing real-time stock levels or locations. Pickers may waste time searching for items that aren’t there or picking the wrong products. This disrupts workflows, increases fulfillment delays, and can lead to dissatisfaction for 3PL warehouse clients.
8 Best Practices for Implementing Batch Picking in Warehouse
Some of the common issues with batch picking can be overcome if you implement it right. Many warehouses lack proactive strategies or rely on outdated software leading to mispicks, inventory inaccuracies, and worker inefficiency in handling complex multi-orders.
Here are 8 best practices you can use to implement batch picking in warehouse operations:
1. Train Pickers on Batch Workflows
Many warehouses don’t give enough training for managing batch orders effectively. You need a comprehensive training plan for pickers to learn how to group items, pick quicker routes, and sort batches into individual orders.
Well-trained staff can reduce errors and send accurate deliveries to the end consumer.
2. Communication with Key Departments
Implementing accurate, open communication between different teams such as sales, marketing, customer service, and packing limits disruptions and improves the batch-picking workflow of incoming orders.
3. Combine Batch Picking with Directed Putaway
To optimize batch picking, you need to reduce the distance your workers travel to complete orders. The directed putaway process uses automated tools like a warehouse management system (WMS) to help you store items in smarter, more accessible locations for easy retrieval.
4. Use Cross-Docking for Time-Sensitive Orders
For smaller inventory spaces, cross-docking uses automated systems to immediately sort orders when shipments arrive and load them onto outbound trucks for delivery without storing them.
This reduces bottlenecks between picking, sorting, and shipping, creating a smooth, streamlined workflow.
5. Test and Adjust Batch Sizes
Experiment with batch sizes that fit your warehouse operations. Batches with more items can increase warehouse efficiency but may hurt accuracy and complicate sorting. However, batches with fewer are easier to handle but may not maximize productivity.
6. Allocate Resources Based on Order Volumes
During peak seasons or sales, the relatively large number of orders often leads to inaccuracies and errors. You need to allocate additional resources to the batch-picking process. These help you organize batch orders or picking stations to manage high order volumes without delays.
7. Analyze Performance and Order Management
Regularly evaluate your workers’ performance, how batches are being processed, and what adjustments you can make in terms of picking speed, order accuracy, and errors. Analyzing data can help you optimize your warehouse operations and identify areas for improvement.
8. Customize Operations
During peak seasons, sales events, or viral trends, fluctuations in order volumes and types can challenge warehouses. Address these challenges by refining batch picking strategies—increasing batch sizes, prioritizing high-demand SKUs, or reorganizing workflows.
Case Study: How Retail Giant Zalando Implemented Batch Picking to Improve Its Warehouse Efficiency
To understand the process, here’s a real-life batch-picking example of how a big enterprise implemented a picking strategy in its warehouse operations.
Zalando, the European online fashion retailer, operates warehouses that manage millions of SKUs and thousands of orders daily. According to a research study, Zalando explored batch picking with advanced algorithms and zoning practices to streamline operations and address its inefficiencies in order fulfillment.
Problem: Inefficiency
Before adopting batch picking, Zalando faced several operational challenges:
- High Travel Times: Warehouse staff spent too much time moving between storage locations, slowing down order fulfillment.
- Suboptimal Item Storage: They used a mixed-shelves storage policy, where identical SKUs were distributed across the warehouse, causing problems with retrieval.
- Complex Order Fulfillment: Managing small orders with diverse SKUs took a lot of time and was prone to errors.
Solution: Batch picking enhanced
To address these issues, Zalando developed a complicated framework, known in academic circles as a Joint Order Selection, Allocation, Batching, and Picking Problem (JOSABPP), to optimize its batch picking strategy. Among the innovative solutions:
- Batch Picking: Items for multiple orders were picked together in a single trip, reducing travel time for pickers.
- Zoning: The warehouses were divided into zones with pickers allocated to each section. Items picked in different zones were later consolidated at sorting stations.
- Optimized Routing: Algorithms like the Distance Greedy Algorithm (DGA) were used to create efficient picker routes and reduce travel distances in each zone.
- Dynamic Real-Time Batching: Zalando adapted this common technique from web and industrial processes for warehouse management, grouping orders dynamically based on that moment’s orders, their urgency and priority, and available pickers.
Results: A new standard
Zalando uses algorithms built around batch picking but tailored to its warehouse needs had game-changing impacts. The new system resulted in reduced travel time, faster sorting and order fulfillment, and better utilization of space.
Ultimately, the company overcame operational roadblocks and set a new standard for large-scale warehouse management.
Optimize Batch Picking with Da Vinci’s Warehouse Management Systems (WMS)
American Economist W. Edward Deming said, “85% of the reasons for failure to meet customer expectations are related to deficiencies in systems and processes…rather than the employee.”
Using a warehouse management system (WMS) to drive the batch-picking process can improve warehouse operations dramatically. Da Vinci WMS allows you to group SKUs into batches, track real-time inventory levels, and optimize picking paths.
The software’s real-time inventory management and operational dashboards provide pickers with up-to-date information for decision-making and help reduce errors. Mobile scanners paired with the system further improve accuracy by verifying items as they’re picked.
The WMS also simplifies sorting and packing by organizing picked items into individual orders, saving time during high-demand periods. Our software facilitates warehouse layout optimization to meet modern supply chain needs.
With cloud-based technology, Da Vinci’s WMS enables real-time data sharing across teams and integrates with e-commerce platforms. This makes it easier to manage batch picking in a modern warehouse environment.
Using these tools, Da Vinci’s WMS facilitates faster, more accurate batch picking while supporting your business’s growth and operational capability.
Learn how you can optimize and transform your warehouse operations by implementing Da Vinci Unified. Request a Demo today.
FAQs
What is an everyday example of “batch picking”?
You’re shopping for snacks and beverages for ten friends. Instead of making separate trips for each item, you collect all the snacks from the snacks aisle and all the drinks from the beverage section in one go. Later, you sort them based on your friends’ preferences. This is exactly how batch picking works in a warehouse.
What is the difference between zone picking and batch picking?
Zone picking assigns pickers to specific sections of the warehouse, where they only gather items from their zone. Batch picking, on the other hand, has one picker collect items for multiple orders in one trip, grouping items into a single batch.
What is batch harvesting?
Batch harvesting, aka batch picking, is a process of grouping multiple orders by similar items and picking them accordingly in a single trip. Mostly used in warehouses, this method improves efficiency by reducing redundant trips for the same SKUs. When paired with a WMS, batch picking becomes even more effective. This is because the system can automate batch grouping and optimize picking routes.
What is the difference between wave picking and batch picking?
Wave picking organizes orders into waves based on criteria like shipping deadlines or delivery schedules. However, batch picking groups orders with similar items to collect them in a single trip. Wave picking is suitable for larger warehouses with diverse inventories. On the other hand, batch picking works best in setups where pickers can collect items from one batch in a single trip and sort them later.
When to use batch picking?
Batch picking works best when multiple orders include similar items. It saves time by grouping these items into batches for pickers to collect in one trip, making sorting faster and more efficient, especially in e-commerce or smaller warehouses.
How do you optimize batch processing?
Batch processing or batching picking can be optimized by leveraging advanced software tools like warehouse management systems (WMS). From inventory management to order picking and shipping, these systems optimize your entire order fulfillment process.
What are the disadvantages of batch picking?
Batch picking might not be suitable for small businesses. It can require advanced equipment and technology, like warehouse management systems, to manage inventory and pick orders in batches. You also may need to train the staff on how to use scanners or navigate through the warehouse for order picking. Also, sorting orders can take a lot of time for companies that have smaller inventory and staff.
What is batch picking used to reduce?
Batch picking reduces a picker’s travel time by allowing them to collect all SKUs for multiple orders in a single trip using smart routing techniques. It also simplifies complex orders by grouping items into batches first and sorting them into individual orders afterward.