In the complex and fast-paced environment of warehousing, the goal is to consistently innovate and discover more efficient methods to maintain the speed and accuracy of picking processes. This quest for efficiency has led to the adoption of various innovative picking strategies, one of which is termed Cluster Picking. Cluster picking has emerged as a game-changer, offering an intelligent solution to meet the demands of today’s fast-paced order fulfilment requirements.
What is Cluster Picking?
Cluster Picking is facilitated by advanced Warehouse Management Systems (WMS) and involves picking multiple orders simultaneously in a single pass through the warehouse. Cluster Picking enables warehouse operations to navigate through the aisles, picking items for multiple orders according to the warehouse pick path, minimising travel time and increasing efficiency.
At the time of waving (releasing the order to the warehouse team for picking), the WMS generates a unique wave number, enabling the user to scan a wave number and select a group of orders under that wave.
Cluster picking offers a middle ground among other picking methods. It is more efficient than discrete picking and less complex than zone-based systems. It reduces travel time, improve pick rates, and is effective in fast-moving, high SKU environments such as eCommerce fulfillment centers.
Below is an overview of how cluster picking compares to other picking methods.
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Watch NowHow Cluster Picking Compares to Other Picking Methods
| Picking Method | How It Works | Best For | Limitations |
|---|---|---|---|
| Discrete Picking | One picker, one order, one trip | Simple, low-volume operations | Time-consuming and repetitive |
| Batch Picking | One picker collects same SKU items for multiple orders at once | Orders with shared SKUs | Requires secondary sorting step |
| Zone Picking | Each picker handles one zone; orders move between zones | High SKU warehouses | Complex coordination between zones |
| Cluster Picking | One picker picks multiple orders at once using grouped totes or bins | Medium to high volume, multi SKU orders | Needs WMS or system to manage clusters |
Benefits of Cluster Picking
1. Increased Picking Efficiency
Cluster Picking significantly improves picking efficiency by reducing the distance travelled per item picked. This picking efficiency not only speeds up the order fulfilment process but also allows for a better allocation of human resources.
2. Reduced Order Fulfillment Time
Faster picking directly translates to quicker order fulfilment and enables warehouses to meet tighter shipping deadlines, helping to improve overall customer satisfaction.
3. Enhanced Order Accuracy
WMS will enable the picker to use barcode scanners and RFID tags to help reduce picking errors and ensure that customers receive the correct items.
5. Adaptability and Scalability
As businesses grow and order volumes increase, Cluster Picking scales to meet the heightened demand without a proportional increase in labour or resources.
6. Cost Reduction
Overall cost reduction for warehouse operations results from efficiencies gained and resource optimisation achieved through Cluster Picking. By minimising travel time, utilising resources more effectively, and improving accuracy, a warehouse can operate more cost-effectively and positively impact its bottom line.
Is Cluster Picking Right For Your Warehouse?
Before you overhaul your picking process, it is important to evaluate whether cluster picking is the right fit for your warehouse. Here’s a quick self-assessment checklist:
- High Order Volume: You are processing a large number of orders daily and need to speed up fulfillment.
- Multi-SKU Order: Your orders commonly include a mix of items from different storage locations.
- Picking Inefficiencies: Your current pickers spend too much time walking or revisiting the same zones.
- Order Accuracy Concerns: You are facing frequent errors due to manual sorting or picker fatique.
Cluster picking is perfect when supported by the right technology such as a WMS that integrates order grouping, route optimisations, and real-time tracking. If you need help integrating cluster picking into your existing system, or want to combine it with automation, mobile devices and barcode scanning – reach out to us. FUJIFILM MicroChannel offers tailored warehouse solutions that can help you streamline your fulfillment with cluster picking.
Embrace Cluster Picking to Improve Efficiency
Cluster Picking is an innovative process that a WMS expert can implement in a warehouse to improve efficiency. By embracing this picking method, warehouses can achieve faster, more accurate, and cost-effective operations and position themselves as competitive players in logistics and supply chain management.
As technology continues to evolve, the future of warehouse management will undoubtedly see even more significant innovations, but for now, Cluster Picking stands out as a key strategy for success.
For more information on how to utilise Cluster Picking in your warehouse management, contact us.
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