5 Ways to Improve Warehouse Picking Efficiency

Warehouse picking is often the most labor-intensive and costly operation in fulfillment centers. According to industry research, picking accounts for 50-60% of total warehouse labor costs. Here are five proven strategies to dramatically improve your picking efficiency.

1. Implement Batch Picking

Instead of picking one order at a time, batch picking allows workers to collect items for multiple orders in a single trip through the warehouse. This strategy can:

• Reduce walking time by up to 40%
• Increase picks per hour from 12 to 30+
• Minimize travel distance between locations

Best for: Single-item orders or orders with similar product profiles.

2. Use Mobile Barcode Scanning

Manual picking is error-prone, with typical accuracy rates around 92-95%. Barcode scanning eliminates most picking errors by:

• Validating the correct item is picked
• Confirming the right quantity
• Preventing wrong-location picks
• Providing instant feedback to workers

Result: 99.7% picking accuracy with proper implementation.

3. Optimize Warehouse Layout

Your warehouse layout directly impacts picking efficiency. Key strategies include:

• ABC Analysis: Place high-velocity items closer to packing stations
• Position-based Routing: Number locations sequentially along pick paths
• Zone Picking: Assign pickers to specific warehouse zones
• Forward Pick Locations: Create dedicated high-traffic pick areas

Impact: 20-30% reduction in pick time with proper layout optimization.

4. Leverage Smart Batching Filters

Not all orders should be picked together. Use intelligent filters to batch orders by:

• Shipping method (standard vs. express)
• Destination country or region
• Order tags (wholesale, subscription, retail)
• Product characteristics (fragile, temperature-controlled)

This ensures faster processing for urgent orders while maximizing efficiency for standard shipments.

5. Provide Real-Time Inventory Visibility

Stockouts and mis-picks often occur due to inaccurate inventory data. Real-time tracking provides:

• Exact quantity by location
• Reserved vs. available stock
• Automatic allocation to pick jobs
• Instant updates when stock moves

Benefit: Eliminate overselling and reduce pick errors from phantom inventory.

Measuring Success

Track these key metrics to measure improvement:

• Picks per hour: Target 25-30 for standard operations
• Pick accuracy: Aim for 99%+ with barcode scanning
• Order cycle time: Time from order placement to shipment
• Cost per pick: Total labor costs divided by picks

Conclusion

Improving warehouse picking efficiency doesn’t require expensive automation. By implementing smart batching, barcode scanning, optimized layouts, and real-time inventory tracking, most warehouses can double their throughput while significantly reducing errors.

Ready to transform your picking operations? Contact FastPash to see how our mobile-first WMS can help you achieve these results.