See how each warehouse method actually works.
Each guide explains when a method works, when it does not, what must be ready first, how workers perform it, what can go wrong, what to measure, and how to run a small test.
Not sure about a term? Open the plain-English glossaryCheck incoming deliveries
Check what arrived, how much arrived, and whether it is damaged before adding it to usable inventory.
Blind receiving: count before seeing the expected amount
Have the receiver count what arrived without seeing the expected quantity. Then compare the count and resolve any difference.
Cross-docking: receive and ship without storing
Move incoming goods directly to an outgoing order instead of storing and picking them again—without losing track of them.
Put received stock in the right location
Tell workers where each received pallet, case, or tote should be stored, then confirm that it went there.
Choose fixed or open storage locations
Decide which items always use the same location and which can use any suitable open space.
Refill pick locations before they run empty
Refill the shelves pickers use from reserve storage before those shelves run empty.
Set low-stock triggers and refill amounts
Set a low-stock trigger and refill amount for each pick location.
Use upcoming orders to plan refills
Use known upcoming orders to refill pick locations before picking starts.
Choose an order-picking method
First choose how orders will be grouped and moved. Then choose paper, scanners, voice, lights, or another way to guide workers.
Pick one order at a time
Complete one order at a time. This is simple to control but can require more walking.
Pick many orders, then sort them
Pick items for several orders in one trip, then sort them into separate orders.
Pick several orders on one cart
Pick several orders in one trip and place each item directly into its order bin on a cart.
Pick by warehouse zone
Assign workers to smaller warehouse areas, then combine their work to complete each order.
Pass an order through several zones
Move an order tote from area to area. Each area adds the items it owes.
Release orders in groups or continuously
Release orders in planned groups, continuously, or with a mixture of both based on deadlines and capacity.
Design a multi-order pick cart
Design the cart bins, labels or displays, loading method, route, and cart handoff as one system.
Sort picked items into order cubbies
Sort picked items into cubbies—normally one cubby per order—then send complete orders to packing.
Bring split orders back together
Bring items picked in different batches or areas back together into complete orders.
Pack and check each order
Check the items, quantities, and shipping requirements before closing the carton.
Stage and load finished orders
Put finished orders in clearly assigned lanes so the correct carrier or route loads them on time.
Inspect and route returned items
Inspect each return, decide what should happen to it, and keep questionable items out of good stock.
Count inventory and fix repeat differences
Count the highest-risk inventory often enough to find and fix the causes of errors.
Build kits with the correct parts
Gather the correct components for a kit and resolve shortages or wrong versions before declaring it complete.
Refill production work areas
Deliver the right materials to production before they are needed without crowding the work area.
Handle warehouse problems consistently
Give common problems—shortages, damage, unreadable labels, and outages—a defined place, owner, and next step.