Pick Face Best Practices for Beginners

Optimizing pick faces is one of the most effective ways for beginners to improve warehouse picking performance. Whether you're running a small fulfillment area or part of a larger distribution center, a few practical best practices bring measurable gains. Below are friendly, actionable guidelines to get you started.

1. Prioritize by velocity (ABC slotting)

Sort SKUs by pick frequency. Place A-items (top 10-20% of SKUs by picks) closest to packing and shipping areas and at comfortable heights. B- and C-items can be placed further away or higher/lower on racks. This reduces travel and time per pick.

2. Keep single-SKU pick faces for high-turn items

When space allows, dedicate one pick face to one SKU for clarity and speed. Single-SKU faces reduce confusion and make counting and replenishment easier.

3. Optimize ergonomics

Place the most frequently-picked items between mid-thigh and shoulder height to reduce bending and reaching. Use stable shelving and clearly marked aisles to keep the picking flow safe and efficient.

4. Standardize labeling and signage

Use consistent, large-format labels that include SKU, description, barcode, and quantity per location. Add visual cues like color-coded zones or shelf-edge labels. This helps new staff and temporary workers pick correctly and quickly.

5. Define replenishment triggers

Set minimum and maximum levels for each pick face and use your WMS to generate replenishment tasks before stockouts occur. For example, if a pick face holds 48 units, set a reorder trigger at 12 units to give replenishment time during busy shifts.

6. Use logical grouping

Group related items together—by product family, shipping frequency, or typical order combinations. This reduces search time and supports zone or batch picking strategies.

7. Support with technology where appropriate

For beginners, start with barcode scanning and a basic WMS. As volume grows, consider pick-to-light, voice picking, or mobile tablets to reduce errors. Ensure any technology mirrors physical pick-face organization.

8. Maintain regular cycle counts on pick faces

Because pick faces are active and prone to shrinkage or misplacement, schedule frequent cycle counts—daily for A-items, weekly for B-items. Accurate pick-face inventory prevents order delays and mispicks.

9. Design for easy replenishment

Reserve buffer locations near pick faces for quick top-up. Make replenishment tasks simple: move full cases from bulk storage to the buffer, then a fast replenish to the pick face. This minimizes interruption to pickers.

10. Plan for seasonality and promotions

Temporarily move promotional or seasonal high-velocity SKUs to prime pick faces during peak periods. After the peak, revert to baseline slotting to keep long-term efficiency.

11. Train pickers and document procedures

Clear standard operating procedures (SOPs) reduce variation. Train staff on pick-face layout, labeling, replenishment triggers, and how to report discrepancies. Friendly, short checklists at the packing station help maintain consistency.

12. Monitor key metrics and iterate

Track picks per hour, pick accuracy, travel distance, and stockouts. Small, data-driven adjustments—like moving a high-pick SKU one aisle closer—can compound into big productivity gains.

Example startup plan for beginners

1. Perform an ABC analysis to identify top SKUs.
2. Assign single-SKU pick faces for A-items at waist height near packing.
3. Create standardized labels and update the WMS with pick-face locations.
4. Set replenishment triggers and train a small team on the process.
5. Monitor performance for four weeks and refine layout based on data.

Following these best practices keeps your pick faces organized, predictable, and efficient. For beginners, the biggest wins come from small changes: improving labeling, moving a few high-volume SKUs, and setting simple replenishment rules. Over time, these habits build a robust picking operation that scales with your business.