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Zone picking(Pick and pass) is one order picking method used by warehouse managers to optimize operations and reduce labor costs. According to one report, order picking takes up as much as 50% of a warehouse\u2019s operation costs. Consequently, selecting the right order picking method is a matter of saving big bucks in your business\u2019s budget.<\/p>\n
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Let\u2019s start with the most basic order picking process: discrete or single order picking. This is where a worker receives an order and walks into the back room or around a warehouse to find the product.<\/p>\n
The route they take is rarely optimized. Rather than picking products for multiple orders as they go, they handle one order after another by:<\/p>\n
They will repeat the process several times throughout the day.<\/p>\n
For small businesses, this makes sense. Introducing a complex picking process when you have a small number of SKUs and a limited number of customers can waste time rather than saving it. On the other hand, as the variety of SKUs increases and more customers enter the mix, discrete order picking becomes inefficient.<\/p>\n
To more profitably manage demand growth, warehouse managers introduce other order picking methods like batch picking or zone picking(Pick and pass) .<\/p>\n
In a batch picking operation, workers pick several units of an SKU for multiple orders, limiting the number of return trips. If seven customers need vacuums, then the vacuums for all seven customers are picked at once.<\/p>\n
Others adopt the zone picking(Pick and pass) methodology, which is also known as zone picking. In this approach, managers divide the warehouse into zones and assign workers to each area. Totes or bins move through each zone, collecting SKUs to fill multiple orders at once.<\/p>\n
Not all SKUs are created equal. Some SKUs may be highly popular while others are ordered infrequently and in bulk. Storing these products sporadically throughout your warehouse can lead to issues like bottlenecks, inaccessible items, and longer pick times.<\/p>\n
On the other hand, a strategically organized pick system that stores items based on their characteristics (i.e., high volume, low volume, hazardous, etc.) allows warehouse managers to train staff on specific inventory management requirements and allocate labor efficiently.<\/p>\n
With the zone picking(Pick and pass) method, low-volume items can be stored further away from the packing and shipping area while frequently ordered items can be positioned closer to the dock, allowing workers to quickly move popular products.<\/p>\n
Zone-based order fulfillment allows workers to grow familiar with their SKU category. They can quickly identify products, increasing their overall efficiency and reducing the number of picking errors.<\/p>\n
Assigning workers to specialized pick locations also increases employee pride and accountability. It reduces the interchangeability of workers, creating a personal investment in the work and building employee engagement which reduces absenteeism and turnover.<\/p>\n
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Cluster Picking vs Smart Picking: <\/b>download the guide to see how selecting the best DTC picking strategy can you time. Up to 50% or more in both picking and packing!<\/p>\n
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