Order Picking Best Practices and Common Mistakes

Effective Order Picking combines smart layout, simple processes, trained staff, and appropriate technology. For beginners, focusing on a few high-impact best practices can yield large gains in productivity and accuracy. Equally important is recognizing common mistakes that undermine performance. This entry presents practical advice and pitfalls to avoid.

Top best practices for beginners:

1. Optimize slotting: Slot SKUs based on velocity—place fast-moving items close to packing and at comfortable heights. Group complementary SKUs that are frequently ordered together to reduce travel and picking time.
2. Use clear labeling and signage: Well-marked aisles, shelf labels, and bin IDs speed up location finding and reduce errors. Consistent naming conventions in your WMS and on labels prevent confusion.
3. Standardize picking procedures: Create documented standard operating procedures (SOPs) for pickers, including how to confirm quantities, handle damaged items, and escalate issues. Standard work reduces variation and training time.
4. Leverage simple technology: Barcode scanners and basic handheld terminals deliver immediate improvements in accuracy and traceability. Even small operations benefit from digital pick lists over paper.
5. Batch and zone smartly: Use batching for repeated SKUs and zone picking for large facilities. Test different batch sizes to find the best balance between travel reduction and sorting complexity.
6. Measure the right KPIs: Track pick accuracy, picks per hour, travel time, and order cycle time. Use these metrics to target improvements and validate process changes.
7. Train and empower staff: Regular training ensures pickers follow SOPs and handle exceptions correctly. Empower operators to suggest improvements—frontline feedback is invaluable.
8. Focus on ergonomics and safety: Keep weight at reachable heights, use appropriate equipment (tuggers, carts), and enforce safe lifting techniques to reduce injuries and downtime.

Common mistakes and how to avoid them

• Poor slotting decisions: Putting slow-moving or heavy items in prime locations wastes picker time. Base slotting on data, not convenience.
• Ignoring inventory accuracy: Inaccurate stock levels lead pickers to wrong locations and cause delays. Regular cycle counts and reconciliation processes keep inventory reliable.
• Overcomplicating early: Implementing complex automation or overly detailed processes before understanding workflow can increase errors and costs. Start with simple fixes that show clear ROI.
• No quality checks: Skipping verification steps leads to higher return rates and customer dissatisfaction. Use barcode scans or simple checklist verifications to maintain accuracy.
• Underestimating training needs: Assuming new hires will 'pick up' the job leads to inconsistent performance. Provide initial hands-on training and refresher sessions.
• Poor communication with packing/shipping: Misalignment between picking and packing creates bottlenecks. Coordinate wave schedules and capacity so downstream teams are prepared.

Practical implementation tips for a small operation

1. Start with a cycle count program to ensure inventory accuracy.
2. Analyze order lines to identify top 20% SKUs that make up 80% of picks and slot them for speed.
3. Create simple pick lists sorted by optimal travel route rather than order number.
4. Introduce barcode scanning for all picks before investing in more advanced systems.
5. Measure improvements over 30–90 days and iterate on processes based on data and staff feedback.

Example of fixing a common problem

A fast-growing online retailer had rising error rates and slower throughput as order volume increased. They introduced three changes: (1) slotting the top 50 SKUs closer to packing, (2) implementing a basic WMS to generate optimized pick lists, and (3) adding barcode verification at picks. Within a month, accuracy improved substantially and onsite travel time per order dropped by 25%, allowing the same staff to handle higher volumes.

When to invest in advanced solutions

• Persistent bottlenecks: If optimized processes and basic tech can’t keep up with order volume, consider automation.
• High labor cost pressure: Automation reduces manual labor needs but requires capital and integration planning.
• Complex SKUs or handling needs: Temperature-controlled picks or hazardous materials may require specialized systems or workflows.

Checklist for beginners implementing best practices

1. Conduct a SKU velocity analysis.
2. Implement basic slotting for top SKUs.
3. Introduce barcode scanning and digital pick lists.
4. Document SOPs and train staff.
5. Measure accuracy and productivity weekly and adjust.

In friendly summary, Order Picking performance grows from deliberate small changes: better slotting, dependable inventory, simple technology, and clear processes. Avoid common mistakes like poor slotting or skipping training. With measured steps and continuous feedback, even small teams can achieve reliable, scalable picking performance that supports customer satisfaction and business growth.