Customer expectations for quick delivery mean that for any ecommerce business, order picking efficiency is critical to maintaining smooth operations and meeting these expectations. Inefficient picking processes lead to costly errors, slow fulfillment times, and customer dissatisfaction. However, businesses can significantly improve accuracy and speed by leveraging the right technology.
Common Issues and How to Resolve Them
High Error Rates: Stock
Using manual workflows – like picking by eye and using a paper picklist, or printing shipping labels first then matching products to them by hand – leads to incorrect shipments, costly returns, and frustrated customers. This usually happens due to human error, and even with the best team in the world, it is almost impossible to avoid when using manual systems – this can be through the repetitive nature of the work, minimal differences between the appearance of products or unfamiliarity with the stock itself.
Solutions:
- Implement barcode scanning, RFID technology, or automated picking systems to remove paper-based manual processes from the warehouse ensuring a high level of accuracy.
- Introduce double-check procedures for high-value or frequently mistaken items to minimize errors.
- Use a Warehouse Management System (WMS) or ERP-integrated real-time inventory tracking solution to maintain accurate stock levels and avoid picking delays through cycle -counts, rolling stock takes and spot checks during daily operations.
Time-Consuming Picking Processes
Lack of structure and logical layout leads to unnecessary movement, longer picking times, and reduced productivity. If pickers spend too much time traveling between storage areas, overall order fulfillment slows down, which could cause shipping delays and/or drive up labor costs.
Manual warehouses miss out on the efficiency of automation. However, there’s no one-size-fits-all approach—using a fashion-focused solution in a furniture warehouse may be less effective than your original manual method.
Solutions:
- Optimize picking routes to minimize travel time (a WMS can be used to do this for you).
- Analyze order patterns and implement batch, wave, or zone picking based on order volume and warehouse layout for maximum order picking efficiency.
- Reduce congestion by improving aisle spacing and workstation placement – place high-demand items near packing stations and optimize storage slotting based on picking frequency.
- Upgrade to digital picking lists, voice-picking systems, or pick-to-light technology to reduce human errors and speed up order fulfillment.
Reliance on ‘Tribal Knowledge’
As a business grows, more staff will be needed in the warehouse. Problems can occur when your processes are very manual and require tribal knowledge – for example, if your team knows where everything is stored from memory – new people coming in will struggle to pick things up quickly and this will reduce the productivity of the whole team. Relying on experienced staff can create a huge bottleneck and increases the risk associated with your operation.
In addition to this, a lack of standardized training leads to inconsistencies in picking speed and accuracy, increasing the likelihood of costly mistakes. Coupled with weak verification processes that allow errors to slip through, you can expect to see an increase in labor to correct these mistakes in the form of returns and replacement orders.
Solutions:
- Standardize best practices, document processes, and leverage a WMS to provide clear, automated picking instructions for every employee.
- Implement structured training programs covering best practices, technology use, and quality control measures. Provide refresher sessions to maintain high performance.
- Introduce automated quality checks such as barcode verification before packing. Encourage accountability with performance tracking and feedback loops
Final Thoughts
Optimizing order picking efficiency isn’t just about speed—it’s about accuracy, cost reduction, and scalability. By leveraging a WMS to provide automation, optimized layouts, and structured training, warehouses can significantly improve fulfillment times and customer satisfaction.
Looking to streamline your warehouse operations? Now’s the time to implement these proven solutions and take your order picking to the next level!
