Decision tool · 4 min

Picking-method selector

Compare one-order picking, multi-order carts, batch sorting, zones, and other common methods.

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Your numbers

Describe your operation

Example values are already filled in so you can see how the tool works. Replace them with measurements from your operation. Results update immediately.

Open the plain-English glossary

Orders per dayCustomer orders completed on a normal operating day.

Example: 800 orders/dayAverage lines per orderAverage number of different products on one order. Quantity does not create another line.

Example: SKU A quantity 2 plus SKU B quantity 1 = 2 lines and 3 unitsActive SKUsDifferent product codes currently stocked or picked during the period being studied.

Example: 4,500 SKUs picked in the last 90 daysWalking + search sharePercent of direct work time spent walking or looking for the correct location or item.

Example: 48 minutes out of 100 = 48%Peak / averageBusiest-hour volume divided by average hourly volume. Use the same time window for both.

Example: 1.8× means the busiest hour has 80% more workPrimary handling unitThe physical unit workers normally pick: an individual piece, a full case, or a mixture.Example: Mostly individual pieces

Show the math and assumptions

The score compares daily lines, products per order, active product count, walking and search time, busy-hour factor, and the unit being picked. It ranks methods; it does not predict speed.

How to read this

The yellow result is the main planning answer. Change any uncertain input to see whether the answer is stable. Treat this as a starting point for a small real-world test, not a promise.

About the score

This is only a relative fit score. It is not a predicted improvement, probability of success, or percentage return.

Pick several orders into separate cart bins

One worker combines travel while each order stays in its own tote or cart position.

85/100

Pick several orders together, then sort them

Works when many orders need the same products and the later sorting step is controlled.

77/100

Divide the warehouse into zones, then combine orders

Useful for a large product range or a building already divided into natural work areas.

54/100

Pick one order at a time

Simple to control and often appropriate when volume or order size is low.

54/100

Move each order tote from zone to zone

Works when zones are balanced and each tote handoff is clear.

35/100

This chooses how to organize the work. It does not yet choose how workers receive instructions—paper, scanners, voice, or lights.

What to check nextTest the top two methods using real order sizes, product sizes, location maps, refill work, common problems, and shipping deadlines.

After the calculation

Test the answer on a small piece of real work.

Measure today’s result first. Write down what success means, what can go wrong, and how workers will continue if the new method fails.

Plan a small trial Build a go-live test