Zone Picking

What is Zone Picking?

Zone picking is a highly efficient method used in warehouses to fulfill customer orders. It involves dividing the warehouse into multiple pick zones, with each zone assigned to specific order pickers. These order pickers are responsible for picking the items only within their designated zone.

The process of zone picking begins when an order is received. The order is then divided into separate zones based on the location of the items within the warehouse. Each zone is assigned to a specific order picker who is familiar with the layout and inventory of that zone. This ensures that the picker can quickly locate and pick the required items.

Once the order picker completes picking the items in their zone, the order is moved to the next zone. This movement is usually facilitated by conveyor systems, which transport the order to the next zone where another picker takes over. This continuous movement of orders from one zone to the next is commonly referred to as 'pick-and-pass.'

Zone picking offers several advantages over other picking methods. Firstly, it allows for specialization and expertise in specific zones, as order pickers become familiar with the layout and inventory of their assigned zone. This familiarity leads to increased efficiency and accuracy in picking operations.

Secondly, zone picking reduces the travel time for order pickers. Since each picker is responsible for a specific zone, they do not need to traverse the entire warehouse to fulfill an order. This significantly reduces the time taken to pick items and increases overall productivity.

Furthermore, zone picking enables parallel processing of orders. Multiple orders can be picked simultaneously in different zones, allowing for faster order fulfillment. This is particularly beneficial in high-volume warehouses where a large number of orders need to be processed within a short timeframe.

Conveyor systems play a crucial role in facilitating the smooth flow of orders between zones. These systems ensure that orders are seamlessly transferred from one zone to the next, eliminating the need for manual transportation and reducing the risk of errors or delays.

In conclusion, zone picking is a highly efficient method of order fulfillment in warehouses. By dividing the warehouse into multiple pick zones and assigning order pickers to specific zones, this method optimizes picking operations, reduces travel time, and enables parallel processing of orders. With the aid of conveyor systems, zone picking streamlines the movement of orders from one zone to the next, ensuring a smooth and efficient workflow in the warehouse.