18 Warehouse Picking Strategies To Improve Accuracy & Efficiency

Efficient warehouse picking is the heartbeat of every successful fulfillment operation. For e-commerce brands, wholesalers, and retailers, the right warehouse picking strategies can significantly reduce costs, improve customer satisfaction, and unlock new levels of performance.

When your picking workflow improves, everything improves! This guide breaks down the most common types of picking in warehouse environments and how a smart strategy drives better order picking efficiency.

Whether you're trying to learn how to fulfill orders more efficiently or simply refine your current warehouse workflows, these proven methods will help you scale with confidence.

Split-Case Picking vs Case or Pallet-Level Picking

Split-case picking (also known as piece picking, each picking, or break pack) is a picking process in the warehouse where workers pull individual units rather than full cases. This makes it ideal for DTC orders, subscription boxes, B2B assortments, and retail replenishment that require mixed SKUs or single-unit quantities. It is the foundation of most e-commerce fulfillment operations because customers rarely order in case-level volumes.

Case or pallet-level picking focuses on bulk movement. Here, workers pick full cartons or entire pallets, making it ideal for wholesale shipments. This method streamlines handling and reduces labor per unit, especially when orders require large quantities of the same SKU.

Picking Approach Per Method Used - Comparison Table

18 Most Used Warehouse Picking Strategies In Fulfillment Centers

Core Picking Strategies

1. Single-Order Picking System (Discrete Picking)

Single-order picking is one of the most straightforward warehouse picking methods, where a single picker completes one full order at a time. Although simple and easy to train, this method involves the highest amount of walking because workers travel the entire warehouse for every order. Despite its limitations, it’s extremely reliable for brands with lower order volume or minimal SKU variety.

Key traits:

• Very easy to implement and operate
• Higher travel time per order
• Minimal system requirements

Ideal for: Small warehouses or early-stage e-commerce brands.

2. Batch Picking

Batch picking groups multiple orders containing similar SKUs so workers can collect everything in fewer trips. By reducing repeated travel to the same location, this method greatly improves the efficiency of order picking within a warehouse. It works best when paired with a WMS that can identify order overlap and build optimized batches.

Key traits:

• Ideal for identical or overlapping orders
• Reduces travel distance
• Often paired with put-wall or sortation workflows

Ideal for: High-volume DTC brands with repeated SKU combinations.

3. Zone Picking

Zone picking divides the warehouse into zones, and each picker remains within their assigned area. This dramatically reduces walking time and helps workers become experts within their zone, improving warehouse order picking accuracy. Orders move through zones sequentially (pick-and-pass picking), or pickers complete their section of the order independently (parallel picking).

* More on the pick-and-pass picking later within the article.

Key traits:

• Reduces picker travel
• Ideal for large SKU assortments
• Works well with conveyorized workflows

Ideal for: Fulfillment centers with large, complex catalogs.

4. Wave Picking

Wave picking organizes orders into time-based batches (waves) that are released at scheduled intervals, often aligned with carrier pickup times, packing deadlines, or labor planning. Pickers usually handle one order at a time, but they only pick the orders assigned to that specific wave.

Key traits:

• Time-scheduled order releases
• Great for aligning with cutoff times & shipping carriers
• Reduces congestion by controlling workflow

Ideal for: High-volume warehouses with strict shipping deadlines.

5. Cluster Picking

Cluster picking allows pickers to walk a single route while fulfilling multiple orders at once using a multi-bin cart or trolley. Because workers pick several orders during a single pass, the total walking distance is significantly reduced. This method is extremely effective for DTC operations with many single-unit orders, where speed and efficiency are essential.

Key traits:

• Multiple orders picked simultaneously
• Reduces travel time significantly
• Supports pick-to-light or pick-to-cart setups

Ideal for: Fast-paced e-commerce warehouse with repeated SKUs across orders.

6. Pick-To-Light

Pick-to-light systems use illuminated displays that guide workers to the exact pick location and quantity. This eliminates the need for paper lists or constant device checking, allowing workers to pick quickly and confidently. The simplicity of light guidance significantly reduces training time and boosts accuracy even in high-volume environments.

Key traits:

• Excellent for speed and accuracy
• Paperless and intuitive
• Easy for seasonal teams to learn

Ideal for: High-throughput pick lines.

7. Put-To-Light

Put-to-light is the inverse of pick-to-light: workers place items into lit compartments based on order assignment. It’s commonly used after batch picking, where many items are retrieved at once and then need to be sorted into individual orders. By automating sorting direction, put-to-light reduces errors and speeds up consolidation.

Key traits:

• Ideal for multi-order sorting
• Greatly reduces sorting mistakes
• Supports batch workflows

Ideal for: Operations using batch or consolidated picking.

8. Pick-To-Voice (Voice Picking)

Voice picking equips workers with headsets that deliver real-time instructions. This hands-free method eliminates the need to carry paper or handheld devices, improving safety and speed. Since workers receive clear verbal directions, picking accuracy often improves greatly.

Key traits:

• Hands-free navigation
• High mobility
• Simple onboarding

Ideal for: Large warehouses or complex pick paths.

9. Paper Picking

Paper picking uses printed pick lists that workers follow through the warehouse. Although it’s the most traditional option, it remains useful in low-tech environments where WMS systems are not yet in place. However, it tends to have the highest risk of human error and slowdowns.

Key traits:

• No technology required
• Easy to start with
• Higher error rate

Ideal for: Small operations with limited tech adoption.

10. RF Picking

RF picking uses handheld scanners and RFID tags that communicate with the WMS to guide workers through their tasks. Every pick is scanned and validated, reducing errors and improving accountability. It’s a major upgrade from paper picking and provides real-time visibility into the warehouse picking process.

Key traits:

• Real-time accuracy checks
• Full software integration
• Strong audit trail

Ideal for: Growing operations needing accuracy at scale.

Automation-Based Picking Strategies

11. Goods-To-Person (GTP) Picking

GTP systems use automation like robots, shuttles, conveyors, or AS/RS to bring items directly to the worker. This eliminates walking through the facility and dramatically shortens the time required per pick. Because every pick happens at an ergonomic station, accuracy and worker safety both increase.

Key traits:

• Minimal walking
• High speed and accuracy
• Scalable with automation

Ideal for: High-volume fulfillment with automation budgets.

12. Automated Storage & Retrieval Systems (AS/RS) Picking

AS/RS systems retrieve totes, cases, or trays using shuttles or cranes, then deliver them to a picker or workstation. This approach allows warehouses to store more SKUs in a smaller footprint while improving speed. With automated retrieval, workers focus solely on picking rather than traveling or searching.

Key traits:

• High-density storage
• Automated retrieval
• Excellent for SKU-rich operations

Ideal for: Businesses needing space efficiency and high precision.

13. Robotic Picking

Robotic picking uses AI-powered arms and mobile robots to identify, grasp, and move products. These robots can operate around the clock, handle repetitive tasks, and reduce reliance on manual labor. As machine vision improves, robotic picking becomes more capable of handling irregular shapes and diverse packaging types.

Key traits:

• 24/7 operation
• High consistency
• Lower long-term labor costs

Ideal for: High-volume operations with repeatable tasks.

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Advanced Picking Strategies

14. Bucket Brigade Picking

Bucket brigade picking uses a progressive handoff logic where workers pass orders down the line to balance workload automatically. Faster workers naturally pick more because they catch up to the slower workers, reducing idle time. This dynamic system requires minimal planning and adapts in real time to the workers’ pace.

Key traits:

• Balances workloads automatically
• Reduces idle time
• No complex planning required

Ideal for: Long aisles with variable worker speeds.

15. Cross-Belt / Tilt-Tray Sorter

These high-speed sortation systems transport items along a moving line and automatically sort them into bins, chutes, or order destinations. Cross-belt systems slide items sideways, while tilt-trays tilt to drop items into the right location. They dramatically increase throughput and eliminate manual sorting.

Key traits:

• Automated high-speed sorting
• Supports large SKU volumes
• Reduces manual handling

Ideal for: Large e-commerce and retail distribution centers.

16. Pick & Pass

In a pick-and-pass workflow (already mentioned in the zone picking strategy), the warehouse is divided into zones, and orders move from one zone to another for processing. The order physically moves from one zone to the next, and each picker adds their items sequentially. Each picker completes the portion relevant to their zone before passing it on. This prevents workers from crossing the entire warehouse and reduces congestion.

Key traits:

• Sequential workflow
• Lower training complexity
• Reduces travel time

Ideal for: Medium and large warehouses with well-defined zones.

17. Two-Stage Picking

Two-stage picking separates picking into bulk collection and final sorting. First, pickers retrieve large batches of items to increase efficiency. Then, items are sorted by order in a consolidation area for packing.

Key traits:

• Increases pick density
• Reduces slow-mover travel
• Ideal with put-to-light systems

Ideal for: Warehouses with both fast- and slow-moving SKUs.

18. Case Picking

Case picking focuses on moving full cases rather than individual units. Workers typically use pallet jacks or forklifts to handle large quantities at once. This improves speed and reduces labor per unit, making it ideal for bulk shipments.

Key traits:

• Efficient bulk movement
• Less labor per unit
• Works well with pallet stackers

Ideal for: Wholesale shipments and pallet-level distribution.

Warehouse Picking Methods Comparison Table

Warehouse Picking Optimization With The Fulfillment Lab

Optimizing your warehouse picking systems is one of the most impactful changes you can make to boost efficiency, accuracy, and customer satisfaction. Whether you’ve outgrown your current workflow, want to increase order picking accuracy, or simply need more speed during peak season, The Fulfillment Lab is here to help.

We combine technology, strategy, and decades of operational expertise to create fulfillment systems that grow with your business.

Ready to improve your warehouse picking with one of the top 3PL providers in the US?

Contact us today!