Whether you’re running a small e-shop or a fast-growing fulfillment center, pick and pack is where precision meets speed – but also where small inefficiencies can quietly stack up.
Optimizing picking and packing within a warehouse means more efficient processing and happier customers.
What Is Pick And Pack?
Pick and pack is a core order fulfillment strategy in warehouse operations when dealing with a diverse product range. It involves retrieving the specific items from your inventory (“picking”), and then preparing them for shipment (“packing”). Extensively used in e-commerce and retail, it aims to prepare orders quickly and accurately, thereby reducing errors and speeding up fulfillment time.
How Does The Pick And Pack Process Work?
To reap all the benefits of picking and packing, every phase must be completed to perfection. Here’s what it usually looks like:
Order Receiving
As soon as a customer places an order, the Warehouse Management System (WMS) or fulfillment software processes it immediately and generates a packing slip listing the required items.
If your business runs more than one pick pack warehouse, the system assigns the order to the one with both sufficient stock and the shortest delivery distance to the customer.
The WMS then gives the order a unique identifier and places it in the picking queue – often based on the chosen shipping speed – so it’s ready for the warehouse team to act.
Order Picking
Once the system receives a customer order, the picking phase begins. With the picking list ‘in hand’, warehouse staff move through the aisles to locate and collect the exact products. They check the quantities and cross-reference them with the list to ensure everything’s correct.
This step plays a crucial role in overall efficiency. In fact, it’s estimated that pickers spend up to 60% of their time simply walking between locations. That’s why picking and packing workflows are often refined with layout tweaks or automation to reduce time lost on the move.
Order Packing
After everything has been picked, the items head to a packing station.
Here, packers choose the right packaging materials – boxes, air pillows, bubble wrap – based on what the product needs to stay safe in transit. Some e-commerce brands may also request custom packaging.
Before the box is sealed, a quick quality control check makes sure the right products are going out, packed the right way. Then, the label is printed and attached.
Together, these steps complete the essential ‘pick pack ship’ process – ensuring order accuracy, speed, and customer satisfaction from shelf to doorstep.
Order Shipping
With everything packed and labeled, the order is ready to go. The WMS typically calculates the most cost-effective shipping method based on the weight, value, and required delivery time.
Packages are then staged near loading docks and arranged for carrier pickup.
Once the orders are out the door, tracking updates go live – keeping both the shipper and the customer in the loop, every step of the way.
Common Picking Strategies In E-commerce (And When To Use Them)
The proper picking method can make a big difference. Factors like warehouse size, order volume, and product types will help you determine which strategy fits best.
Piece Picking (or Discrete Picking)
This simple method works well for smaller businesses with fewer orders. A picker completes one order at a time, collecting every item before moving on to the next. It’s accurate—but not ideal for large operations, as travel time adds up quickly.
Batch Picking
As the name suggests, in batch picking, the picker gathers the same product for several orders in one go. This cuts down on walking and speeds things up. It’s a smart choice when you deal with lots of smaller orders, especially if many of them share the same SKUs.
Zone Picking
Here, the pick and pack warehouse is split into different zones. Each picker is responsible for just one zone, collecting items only from their assigned area.
If an order needs items from more than one zone, it moves between pickers until it’s complete. This approach keeps travel time down and works well in larger spaces—or when dealing with products that require special handling.
Wave Picking
Wave picking blends the zone and batch methods. Orders are grouped into “waves” based on criteria like shipping priority, product type, or carrier routes.
Pickers then work on these waves, within zones or in batches. It’s a great option when you’re juggling high volumes and need to prioritize urgent orders, while still leveraging batch efficiencies.
However, it’s a complex pick & pack method that requires a sophisticated warehouse and inventory management system as well as strong coordination among staff.
Improving Your Pick & Pack Operations
Keeping your pick and pack operations sharp isn’t a one-time thing; it’s a habit. Here are a few ways to do it better:
Streamline Workflows & Optimize Layout
Identify bottlenecks and eliminate unnecessary steps. Optimize your pick and pack warehouse layout to shorten travel times and keep high-volume items close to the shipping area. Even small layout adjustments like this can significantly reduce picking time.
Invest In Staff Training
Give your warehouse team proper training on picking techniques, equipment use, and new technologies. A well-trained team moves faster, more safely, and adapts better to changing processes.
Implement Quality Control Checks
Integrate checks at various points throughout the picking and packing process. This approach will help you catch errors early. Additionally, make it a habit to conduct audits and gather employee feedback to spot trends and fix problems before they grow.
Monitor & Measure Performance
Track key performance indicators (KPIs) such as picking accuracy, order fulfillment cycle time, and customer complaints and returns. Collecting and analyzing real-time data enables you to uncover hidden bottlenecks and make data-driven decisions. In fact, companies using data-driven decision-making are 23% more likely to exceed industry profitability benchmarks.
From Pick to Peak: Fulfillment That Moves You Forward
Order fulfillment doesn’t need to feel like a steep climb. At Agile SCS, we make the pick & pack process smooth, reliable, and refreshingly simple – whether you’re shipping to a customer’s front door or stocking retail shelves.
We take care of the hard parts – like kitting, assembly, labeling, and routing – so you can focus on what you do best: growing your business. With smart packaging and lower shipping costs, your products move faster and more efficiently.
From pick to pack to ship, we’re here to help you scale – step by step, box by box. Ready to elevate your order fulfillment and climb to new heights? Let’s climb together!