How to Implement Batch Picking in Your Warehouse

What is Batch Picking and Why Should You Implement It?

Batch picking is a warehouse order fulfilment strategy where pickers collect items for multiple orders simultaneously during a single trip through the warehouse. Rather than completing one order before starting the next (single-order picking), batch picking groups similar orders together to reduce travel time and increase efficiency.

Implementing efficient picking strategies is essential for reducing costs and improving customer satisfaction. Batch picking can dramatically increase picking productivity—often by 30-65% compared to single-order methods—while reducing labour costs and improving order accuracy.

“The warehouse walking pattern is one of the biggest hidden costs in fulfilment operations. When implemented correctly, batch picking can reduce travel time by up to 40%, instantly transforming your productivity without requiring expensive automation.” — David, Business Director at PALLITE

Key Benefits of Batch Picking

Increased Productivity

By collecting items for multiple orders in a single warehouse trip, pickers spend significantly less time walking between locations. This efficiency gain often translates to 2-3 times more orders processed per labour hour compared to single-order picking methods.

Reduced Labour Costs

With higher productivity rates, warehouses can fulfil the same order volume with fewer staff hours or handle increased volume without proportional staffing increases. Many operations report 20-30% labour cost reductions after successfully implementing batch picking.

Improved Order Accuracy

Structured batch picking processes typically incorporate verification steps that reduce error rates. Well-designed batch picking systems can improve order accuracy from industry averages of 96-97% to 99% or higher.

Enhanced Space Utilisation

Batch picking often enables more efficient storage strategies as it reduces the need for easy accessibility to all products simultaneously. This can lead to increased storage density and better utilisation of vertical space.

Scalability During Peak Periods

Batch picking methods scale more efficiently during high-volume periods, helping warehouses manage seasonal spikes without proportional increases in staffing or dramatic changes to workflows.

Is Batch Picking Right for Your Warehouse?

While batch picking offers significant benefits, it’s not universally appropriate for all warehouse operations. Consider these factors when determining if batch picking is right for your facility:

Ideal Scenarios for Batch Picking

Batch picking works best in warehouses with:

• High volumes of small to medium-sized orders
• Multiple orders requiring the same or nearby SKUs
• Products that can be easily sorted after picking
• Limited SKU count relative to order volume
• Consistent order profiles with predictable patterns

When Other Methods Might Be Better

Alternative picking methods might be more appropriate if your warehouse has:

• Primarily large, bulky items that are difficult to batch
• Very large orders that consume entire picker capacity
• Extremely time-sensitive orders requiring immediate processing
• Highly variable order profiles with minimal commonality
• Products requiring special handling that complicates batching

Step-by-Step Implementation Guide

Successfully implementing batch picking requires careful planning and execution. Follow these steps to transition efficiently:

1. Analyze Your Current Operations

Before making any changes, thoroughly analyze your current picking operations to establish baseline metrics and identify improvement opportunities:

• Calculate your current picking productivity (orders per hour, lines per hour)
• Document walking patterns and travel time percentages
• Identify your most common order profiles and SKU demand patterns
• Evaluate your error rates and types of picking mistakes
• Assess your current technology capabilities and limitations

This analysis provides the foundation for designing an optimized batch picking process tailored to your specific operation.

2. Design Your Batch Picking Process

Based on your operational analysis, design a batch picking process that addresses your specific needs and constraints:

Determine Optimal Batch Sizes

The ideal batch size balances walking efficiency with complexity management. Larger batches reduce walking time but increase sorting complexity and error risk. Most operations find optimal efficiency with batch sizes of:

• 8-15 orders for paper-based systems
• 12-25 orders for RF scanner-based systems
• 20-40 orders for voice or light-directed systems

Test different batch sizes to find the sweet spot for your operation.

Choose a Batching Method

Select from several approaches to grouping orders into batches:

• Wave Batching: Creating batches from a set of orders released simultaneously
• Order Value Batching: Grouping orders of similar value to balance picker workload
• Zone Batching: Grouping orders that require picks from the same warehouse zones
• SKU Commonality Batching: Combining orders with the highest percentage of shared items
• AI-Driven Batching: Using algorithms to optimise batches based on multiple factors

The right method depends on your warehouse layout, order profiles, and technology capabilities.

Design the Physical Picking Setup

Create a physical picking setup that supports your batch methodology:

• Cart Configuration: Design picking carts with clearly marked locations for each order
• Tote Systems: Implement colour-coded or labelled totes for order separation
• Mobile Workstations: Consider ergonomic mobile workstations with integrated technology
• Sorting Areas: Designate appropriate post-pick sorting spaces if needed

“We’ve seen tremendous success with modular picking cart solutions combined with our PIX units in the picking zones. This combination allows warehouses to quickly reconfigure their batch picking setup as order profiles change, without disrupting the entire operation.” — David, Business Director at PALLITE

3. Update Your Technology Systems

Most warehouse management systems (WMS) support batch picking, but configuration changes are typically required:

WMS Configuration

Work with your WMS provider to:

• Enable batch picking functionality
• Configure optimal batching algorithms
• Set up pick path optimization
• Create batch picking-specific reporting
• Implement verification processes

Consider Supporting Technologies

Depending on your operation scale, these technologies can enhance batch picking effectiveness:

• RF Scanners: Provide real-time direction and verification
• Voice Picking: Enables hands-free operation for faster picking
• Pick-to-Light Systems: Visual indicators reduce errors and increase speed
• Mobile Printers: Allow on-demand label printing during picking
• Put Walls: Facilitate efficient sorting after batch picking

4. Develop Standard Operating Procedures

Create detailed standard operating procedures (SOPs) that document every aspect of your batch picking process:

• Batch creation and release procedures
• Step-by-step picking instructions
• Exception handling protocols
• Order verification methods
• Performance standards and expectations
• Troubleshooting guidelines

Well-documented procedures ensure consistency across shifts and personnel, reducing errors and training time.

5. Train Your Team

Comprehensive training is critical for successful implementation:

Training Components

Develop a training program that includes:

• Classroom instruction on batch picking concepts
• Hands-on practice with actual equipment
• Side-by-side shadowing with experienced pickers
• Progressive responsibilities as proficiency increases
• Regular knowledge checks and performance feedback

Address Change Management

Recognize that transitioning to batch picking represents significant change for experienced pickers:

• Clearly communicate the reasons for the change
• Address concerns about new performance expectations
• Highlight benefits for pickers (less walking, more ergonomic)
• Involve experienced staff in process design and refinement
• Consider incentives during the transition period

6. Pilot Implementation

Rather than implementing batch picking across your entire operation immediately, start with a controlled pilot:

• Select a specific area or order type for initial implementation
• Choose your most adaptable team members for the pilot
• Establish clear success metrics and evaluation criteria
• Run the pilot for sufficient time to identify issues (2-4 weeks)
• Document all challenges and improvement opportunities

A successful pilot builds confidence and provides valuable insights before full implementation.

7. Scale and Optimize

After a successful pilot, gradually expand batch picking across your operation:

• Roll out in phases based on order types or warehouse zones
• Continue training as implementation expands
• Regularly analyze performance data to identify bottlenecks
• Make incremental improvements to processes and equipment
• Document best practices specific to your operation

Common Challenges and Solutions

Even well-planned batch picking implementations face challenges. Here are common issues and proven solutions:

Challenge: Increased Sorting Complexity

Solution: Implement clear order separation systems like:

• Color-coded totes or cart locations
• Barcode verification during sorting
• Put-to-light systems for high-volume operations
• Sorting stations with visual management tools

Challenge: Higher Error Rates During Transition

Solution: Enhance verification procedures:

• Implement two-step verification for high-value items
• Use technology to confirm correct item selection
• Create quality check stations for randomly selected orders
• Provide immediate feedback when errors occur

Challenge: Resistance from Experienced Pickers

Solution: Focus on change management:

• Involve experienced staff in process design
• Highlight reduced walking and physical strain
• Implement temporary performance standards during transition
• Create peer mentors to support struggling team members
• Share performance improvements and celebrate successes

Challenge: Handling Product Size Variations

Solution: Develop specialized approaches:

• Create separate batch processes for different product sizes
• Design flexible cart configurations that accommodate various items
• Implement hybrid systems where appropriate (batch for small items, single-order for large)
• Use movable dividers in picking containers to adjust as needed

Challenge: Technology Limitations

Solution: Find appropriate technology solutions:

• Upgrade WMS if necessary to support advanced batching
• Implement mobile technologies with real-time updates
• Consider voice systems for complex batch picking
• Use simple paper-based systems as backup for technology failures

Measuring Success and Continuous Improvement

Implementing batch picking isn’t a one-time project but an ongoing process of measurement and refinement:

Key Performance Indicators

Track these metrics to evaluate your batch picking effectiveness:

• Picks Per Hour: The number of order lines picked per labor hour
• Orders Per Hour: The number of complete orders fulfilled per labor hour
• Travel Time Percentage: The portion of picking time spent walking
• Error Rates: The percentage of orders with picking errors
• Labor Cost Per Order: The total labor cost divided by order count
• Space Utilization: How efficiently warehouse space is being used

Continuous Improvement Strategies

Implement these approaches to drive ongoing performance gains:

• Regular Performance Reviews: Analyze KPIs weekly to identify trends
• Picker Feedback Sessions: Gather insights from frontline staff
• A/B Testing: Test process variations to identify improvements
• Cross-Training: Develop versatile team members who can work across functions
• Technology Evaluation: Continuously assess new picking technologies

“The most successful operations we work with view batch picking as an evolving process. They’re constantly analyzing data, making small adjustments, and testing new approaches. This continuous improvement mindset typically yields an additional 15-20% efficiency gain beyond the initial implementation benefits.” — David, Business Director at PALLITE

Advanced Batch Picking Strategies

Once you’ve mastered basic batch picking, consider these advanced strategies to further enhance performance:

Cluster Picking

Cluster picking is an enhanced form of batch picking where pickers use specially designed carts with multiple totes to collect items for 4-12 orders simultaneously. Each order has a dedicated tote, eliminating the need for post-pick sorting.

Implementation Requirements:

• Multi-tote picking carts with clear order designation
• Technology support for directing items to correct totes
• Optimized warehouse layout for cart movement
• Pick-to-light or voice systems for greater efficiency

Pick-and-Pass Batch Picking

This strategy combines batch picking with zone picking, where each picker works within a specific zone and passes partially completed batches to the next zone.

Implementation Requirements:

• Clearly defined picking zones based on item velocity
• Conveyor systems or transfer stations between zones
• WMS support for zone-based batch picking
• Balanced workload across zones to prevent bottlenecks

Dynamic Slotting with Batch Picking

This approach continuously optimizes item locations based on order patterns to enhance batch picking efficiency.

Implementation Requirements:

• WMS with dynamic slotting capabilities
• Regular slotting analysis and adjustment processes
• Flexible storage solutions like PALLITE PIX units
• Staff trained on regular location changes

Batch Picking Equipment and Solutions

The right equipment significantly impacts batch picking success:

Picking Carts

Invest in purpose-built batch picking carts designed for your specific operation:

• Multi-Order Carts: Designed with separate compartments for each order
• Adjustable Configurations: Flexible dividers to accommodate different order sizes
• Ergonomic Design: Proper height and accessible compartments to reduce strain
• Maneuverability: Easy movement through warehouse aisles
• Technology Integration: Mounts for RF scanners or mobile devices

Storage Solutions

Optimise your storage system to support efficient batch picking:

• Forward Pick Areas: Dedicated zones for high-velocity items
• Flexible Racking: Adjustable solutions that adapt to changing inventory
• High-Density Storage: Maximising space while maintaining accessibility
• Modular Systems: Solutions like PALLITE PIX units that can be reconfigured as needed
• Visual Management: Clear location labelling and directional indicators

Technology Solutions

The right technology stack enhances batch picking effectiveness:

• WMS with Batch Capabilities: Software specifically designed for batch optimization
• Mobile Devices: Rugged tablets or smartphones with picking applications
• Wearable Scanners: Ring scanners that free up picker hands
• Voice-Directed Systems: Headsets that provide verbal picking instructions
• Pick-to-Light: Visual indicators showing which items to pick

Conclusion

Implementing batch picking in your warehouse can deliver substantial improvements in productivity, cost efficiency, and order accuracy. By following a structured implementation process and addressing common challenges, you can successfully transition from single-order picking to more efficient batch methods.

Remember that successful implementation requires thorough planning, appropriate technology, well-designed processes, and comprehensive training. Start with a clear analysis of your current operations, design a batch picking system that addresses your specific needs, and implement in phases to increase warehouse efficiency.

The most successful operations view batch picking implementation as an ongoing journey of continuous improvement rather than a one-time project. By regularly analysing performance data and refining your approach, you can continue to enhance efficiency and maintain competitive advantage in an increasingly demanding fulfilment environment.

“When we help customers implement batch picking with our flexible storage solutions, we emphasise that the initial implementation is just the beginning. The warehouses that achieve the greatest success are those that continue measuring, adjusting, and improving their processes. With the right approach, batch picking can transform warehouse operations from a cost centre to a genuine competitive advantage.” — David, Business Director at PALLITE