Pick Face: What it Is and Why It Matters

Pick face refers to the visible, reachable side of a storage location where items are picked for orders. For a beginner, it helps to imagine the pick face as the "front line" of inventory: the places a picker reaches into to grab a product. Pick faces can be on pallet racks, bins, shelving, or flow racks, and they are organized so pickers can access goods quickly and accurately.

Understanding pick faces is important because they directly affect picking speed, accuracy, and labor costs. In many operations, optimizing pick faces yields more immediate gains than larger capital investments. A well-designed pick face strategy reduces travel time, minimizes mistakes, and improves throughput during peak seasons.

Common types of pick faces include:

• Single-SKU pick face: Each pick face holds one stock keeping unit (SKU). This simplifies picking and counting and is common for high-velocity items.
• Multi-SKU pick face: Multiple SKUs share a single pick face, often used in small-parts or piece-pick environments where physical space is limited.
• Case pick face: Pick faces configured so workers pick full cases or cartons. Common in distribution centers handling palletized goods.
• Unit/each pick face: Designed so workers pick individual items (units) rather than full cases.

Key characteristics of a good pick face layout:

• Accessibility: Items should be within comfortable reach without excessive bending or stretching. This increases speed and reduces injuries.
• Visibility: Labels and barcodes should be easy to see and scan from the walking aisle to reduce mispicks.
• Proximity: High-velocity SKUs should be positioned closest to packing and shipping areas to minimize travel distance.
• Logical grouping: Grouping SKUs by order frequency, product family, or shipping method simplifies picker movement and reduces cognitive load.

Real-world example

In an e-commerce fulfillment center selling apparel, small, fastest-moving T-shirts might be placed at waist height on shelving near packing stations (single-SKU pick faces), while bulky winter coats are placed on upper racks or in bulk storage and replenished to lower pick faces when demand spikes.

How pick faces interact with technology

Warehouse Management Systems (WMS) and slotting software often determine pick-face assignments and replenishment triggers. A WMS can guide pickers through the most efficient route and ensure a pick face is replenished before stockouts occur. Barcode labels, pick-to-light, and voice picking systems also rely on consistent pick-face organization to operate effectively.

Metrics to monitor pick-face performance include picks per hour, travel distance per pick, pick accuracy (error rate), and stockout frequency at pick faces. Tracking these metrics helps identify whether pick faces are well-positioned and managed or need adjustments.

Beginner tips

• Start by identifying your top 20% SKUs that generate 80% of picks (ABC analysis) and place them on the best pick faces.
• Keep accurate labeling and ensure barcodes face the aisle to speed scanning.
• Designate clear replenishment routines so pick faces don’t run empty during shifts.
• Measure and iterate: small changes in pick-face placement can yield significant productivity gains.

In short, the pick face is a simple but powerful concept. Small, thoughtful changes to pick-face layout and management often deliver outsized improvements in efficiency, accuracy, and worker satisfaction in a warehouse. For anyone learning warehouse operations, mastering pick-face basics is one of the quickest ways to impact performance.