What does order picking mean?

Essentially, it involves removing items from different storage areas, combining them into an order unit, and preparing them for shipping or further processing. The picker works on the basis of pick lists that are either created manually or generated automatically via a warehouse management system (WMS).

But picking is more than just “picking” items—it is a key success factor in modern logistics. Those who consistently digitize and optimize their processes in this area not only increase efficiency in the warehouse, but also ensure long-term competitiveness in retail and industry.

Overview of picking methods

1. By organization:

• Serial picking: An order is processed sequentially through different storage areas.
• Parallel picking: Different storage zones work on an order simultaneously.
• Chaotic picking: Items are not stored in fixed locations but are retrieved using a system-controlled process.

2. By degree of automation:

• Manual picking: Employees retrieve items independently (e.g., using pick lists or mobile scanners).
• Automated picking: Robots, conveyor technology, or automatic small parts warehouses take over the process.
• Semi-automated picking: Humans and technology work together, for example, via pick-by-light, pick-by-voice, or pick-by-scan systems.

Significance in logistics and challenges

Order picking is one of the most cost- and time-intensive processes in warehouse logistics. Since it requires a lot of personnel and time, it accounts for a significant portion of the total costs in the warehouse. Its importance is particularly evident in its direct impact on delivery quality: Incorrect or delayed picking can lead to delivery delays, returns, or even production downtime—with corresponding negative consequences for customer satisfaction and profitability.

At the same time, picking is associated with numerous challenges. These include, among other things, the high variety of products, which requires flexible and precise picking of items. Added to this are the ever-growing expectations for fast deliveries, especially with offers such as same-day delivery. Highly fluctuating order volumes, for example due to seasonal peaks, also require a high degree of adaptability in processes. Last but not least, manual picking is prone to errors. Well-thought-out process design and, where necessary, technological support are therefore all the more important.