How To Implement Split Case Picking In A WMS-Driven Warehouse

Split Case denotes a case from which less than the full case quantity is picked or distributed. Implementing split-case processes in a WMS-driven warehouse changes inventory tracking, slotting, replenishment, and user-interface workflows; careful configuration prevents errors and preserves inventory accuracy.

Start by aligning your WMS capabilities with operational realities: it must support unit-level inventory, handle fractional-case decrements, and enforce barcode scanning to prevent phantom stock or mis-allocated quantities. The following steps outline a practical implementation path for facilities moving from full-case to split-case or for those looking to improve existing split-case operations.

Step 1 — Profile Order Data And SKU Behavior

Analyze order history to identify SKUs that will be split frequently. Metrics to extract: percentage of orders requiring less-than-case quantities, average units per order, and velocity by SKU. Use this data to decide which SKUs need dedicated forward-pick slots and which can remain in bulk reserve.

• Data Needed: Order lines with unit quantities, frequency of fractional-case picks, and returns/expiry attributes.
• Decision Rule: Place SKUs with high split-case demand in forward pick positions sized for expected pick quantities.

Step 2 — Configure WMS For Fractional Inventory

Ensure your WMS handles unit-level serials or lot-tracking and decrements case quantities correctly after partial picks. Configure pick logic to prefer forward pick locations and trigger replenishment from reserve before pickers must travel to full-case areas. Build pick templates that show remaining quantities in the source case so pickers know how many units are left.

• Transaction Rules: Support split-case pick transactions that update both the unit and case-level records.
• Replenishment: Set min/max levels and automatic replenishment rules for forward pick slots used by split-case SKUs.

Step 3 — Design Storage And Pick-Face Layout

Slotting for split-case SKUs prioritizes accessibility and ergonomics. Use shelving or flow racks as forward pick faces and reserve pallet or bulk racking for full-case stock. Label pick faces clearly and place high-turn split-case SKUs at waist-to-shoulder height to reduce bending.

• Slotting: Assign split-case SKUs to high-visibility, low-travel locations near packing stations.
• Protective Packaging: Provide bins or secondary packs to protect product when cases are opened and partially used.

Step 4 — Standardize Picking Procedures And Training

Create standard operating procedures for split-case actions: how to record the pick, label remaining cases, handle damaged units, and reconcile partial-case counts. Train staff on scanning requirements, pick confirmation steps, and replenishment procedures. Include instructions for lot/expiration tracking if required.

• Labeling Standard: Immediately relabel opened cases with the remaining unit count and lot information if required.
• Scan Enforcement: Make scanning mandatory at pick and at pack to reduce inventory discrepancies.

Step 5 — Use Technology To Reduce Error And Time

Implement technologies that speed split-case picks and cut errors: voice picking, pick-to-light, mobile barcode scanning, and automated replenishment alerts. For very high-volume split-case SKUs, consider automation such as robotic goods-to-person or mini-load systems to reduce manual travel.

• Voice/Scanner: Use voice or handheld scanning to verify SKU and quantity during each pick.
• Analytics: Monitor split-case KPIs in dashboards to spot trends and adjust slotting or pack practices.

Step 6 — Monitor KPIs And Iterate

Track metrics that reflect the true cost and quality of split-case handling: picks-per-hour for split SKUs, cost-per-split-pick, packing time per order, inventory accuracy, and replenishment frequency. Use these KPIs to decide when to pre-kit common order combinations or convert frequently split SKUs into multi-pack inner cartons to reduce handling.

• Key Metrics: Units-per-hour (split), cost-per-order, replenishment cycles, and inventory write-offs.
• Continuous Improvement: Reassign slotting monthly or quarterly based on velocity changes.

Practical Example

A mid-sized fulfillment center automated its split-case workflow by creating forward pick shelves for 200 high-velocity SKUs, configuring its WMS to decrement case counts on partial picks, and enforcing scan-at-pack. They also pre-kitted the ten most common order combinations into ready-to-ship cartons during night shifts. The changes reduced split-case pick time by 18% and cut packing errors by half.

In short, the Split Case requires deliberate WMS configuration, slotting, training, and measurement; when implemented with clear procedures and adequate technology, split-case picking can meet small-order service levels while controlling the incremental labor and inventory risks that come with breaking cases.