Pick-by-Scan

Pick-by-Scan (also known as paperless picking) is a widely used, IT-supported process in intralogistics that enables goods to be picked. With this method, warehouse staff receive their picking orders entirely digitally on a mobile data terminal (MDT). By scanning barcodes or QR codes at the storage locations and directly on the items, every item removal is recorded and automatically synchronized with the higher-level warehouse management system (WMS).

Pick-by-Scan vs. Pick-by-Paper

These two terms describe two fundamentally different approaches to order fulfillment in the warehouse.

• Pick-by-Scan operates entirely paperless, as data is transmitted in real time via wireless communication (Wi-Fi or cellular) to the MDE device. This eliminates manual data entry steps, and errors are detected immediately upon scanning.
• With Pick-by-Paper, on the other hand, order picking is carried out in the traditional manner using printed paper pick lists. The items picked must be manually checked off by the employee, and the inventory levels must later be entered into the system by hand. This results in a significantly higher error rate.

How It Works and Technical Features

The picking process follows a clear, digitally guided sequence. First, the picker requests the next order via their MDE device. The device then displays the route optimized for efficiency. Upon arrival at the destination, a three-step verification process takes place: First, the employee scans the barcode of the storage bin to confirm the location, then the barcode of the retrieved item, and finally confirms the quantity. In the event of a routing error or incorrect item retrieval, the device immediately triggers a visual or audible alarm.

Specific technical equipment in the warehouse is necessary for this smooth operation. At the heart of the system are the MDE devices (mobile data terminals, rugged industrial smartphones, or wrist-worn wearables). These are often combined with so-called ring scanners (finger or backhand scanners) so that the employee has both hands free for the actual picking process. Seamless labeling of all storage locations, shelves, and items with unique barcodes (such as the EAN code) or 2D codes is an absolute prerequisite for this.

Key advantages and disadvantages at a glance

Advantages:

• Minimal error rate: Continuous digital cross-checking of scans virtually eliminates incorrect deliveries.
• Real-time transparency: Inventory is immediately deducted from the system, enabling continuous inventory tracking.
• Efficiency: Eliminating paper lists saves time and significantly shortens the training period for new employees.

Disadvantages:

• Investment costs: The purchase of hardware and software integration require an initial financial investment.
• Dependencies: The system relies on a stable wireless infrastructure and fully charged device batteries.
• Ergonomic limitations: Traditional handheld scanners tie up one of the employee’s hands during picking.