Operations guide · Picking
Pick Routes, Pick Lists and Wave Planning
Once the method is chosen, the next question is: in what order, and in which groups, will tasks run? Routing sets the aisle / location sequence; a consolidated pick list brings several lines together on one list; a wave splits the work into time slots by cut-off and capacity.
Pick routes
The route decides the order in which the operator visits locations. The goal is to reduce empty walking and doubling back.
- Aisle strategies such as S-shape (serpentine), return and midpoint
- Whether location numbering matches the route
- Sequencing heavy / fragile items (bottom/top rules)
- Route deviations while replenishment is open
Consolidated pick lists
A consolidated pick list combines several order lines into one tour / one document. It is the list form of batch picking: items are picked by item and location, then sorted into orders.
Its quality depends on correct allocation, correct sortation and barcode discipline. Allocation: picking priority; methods: picking methods.
Wave planning
A wave answers “which work is released now?”. Carrier cut-offs, dock appointments, shift capacity and stock readiness are considered together.
- Filter candidate orders (SLA, stock, channel)
- Choose the wave size by capacity
- Release → create tasks
- Monitor progress and congestion (packing / staging)
A wave that is too large chokes the pack stations; one that is too small lowers productivity.
Method vs route vs wave
| Layer | Question |
|---|---|
| Method | Single, batch or zone? |
| Wave | When, and in which group, does this work run? |
| Route / pick list | In what order, and on which list, on the floor? |
Selection framework: which one, when?
Measurement
Tour distance, lines per hour, wave completion time, packing queue, cut-off success rate.