What are the biggest time wasters in order picking?

The biggest time wasters in order picking are unnecessary movements across the warehouse floor, search time caused by an unclear or inefficient layout, and correcting errors after a wrong pick. Together, these factors can consume a significant portion of available work time without a single additional order being processed. In this article, we answer the most frequently asked questions about order-picking efficiency, from the causes to concrete solutions.

Which steps in the picking process take the most time?

Most of the time spent in a picking process is lost to moving between locations, searching for the right items, and waiting for instructions or confirmations. Research conducted in warehouse environments consistently shows that moving and searching together account for more than half of the total picking time, while the actual act of picking an item takes up only a fraction of that time.

That makes the picking process fundamentally different from what it seems: the physical act of picking up an item is rarely the bottleneck. The real time-wasters are the steps surrounding it:

• Movement: walking or driving from one location to another, often over long distances if the warehouse layout is not tailored to the picking frequency of items.
• Search: time wasted trying to locate an item because the location label is unclear, the item has been misplaced, or the inventory is incorrect.
• Waiting: for a forklift blocking a location, for a coworker using the same path, or for confirmation from an order system.
• Document processing: Reading, interpreting, and checking off items on a picking list takes more time than expected, especially if the list isn't organized logically.

If you want to optimize the picking process, it’s best to start by timing each step. Only then will it become clear where the real gains can be made.

How does poor warehouse layout affect picking speed?

Poor warehouse layout directly reduces picking speed by forcing pickers to walk unnecessary distances. When fast-moving items are located far from the shipping zones, or when related products are scattered throughout the warehouse, the walking time per order increases significantly. This is one of the most underestimated time wasters in order picking.

An efficient layout is based on picking frequency: items that are picked frequently should be stored close to the shipping area and at an ergonomically accessible height. Items that are rarely requested can be stored farther away or higher up. This principle is called slotting and is one of the most impactful measures for warehouse productivity.

Routing also plays a role. If aisles are too narrow for two-way traffic, or if the walking route through the warehouse isn’t logically aligned with the order on the pick list, every picker systematically loses time. A well-designed layout ensures that a picker can move through the warehouse in one fluid motion without having to return to zones they’ve already visited.

For specific material flows, such as pallet handling or box handling, the layout also requires the right tools to be in the right place, so that pickers do not have to wait unnecessarily for equipment.

Why do picking errors result in additional time loss?

Order-picking errors trigger a chain of additional steps: the incorrect item must be put back, the correct item must be located, the order must be corrected, and in some cases, a return must be processed. As a result, each error takes several times as long as the original picking operation.

The most common causes of picking errors are:

• Unclear or similar item numbers and packaging that looks similar.
• Outdated or incorrect inventory data in the system.
• Time pressure that leads to less accurate checks during the picking process.
• Fatigue caused by repetitive or physically demanding tasks.

In addition to the direct loss of time, a high error rate also has indirect consequences: customer complaints, returns processing, and additional administrative work. In a competitive environment, these costs have a significant impact on overall warehouse productivity. Reducing errors is therefore one of the fastest ways to improve the efficiency of a picking process without major investments.

What is the difference between batch picking and single-order picking?

In single-order picking, a picker processes one order in its entirety from start to finish before moving on to the next one. In batch picking, a picker gathers multiple orders at once during a single round through the warehouse. The difference in efficiency lies in travel time: batch picking significantly reduces the total number of routes through the warehouse.

Both methods have their own areas of application:

• Single-order picking is easy to manage, less prone to errors, and suitable for large or complex orders that require full attention.
• Batch picking is more efficient for small orders with few item lines, because the picker can process multiple orders in a single route. However, it does require a good sorting system to correctly distribute the items by order after picking.

A third option is zone picking, in which the warehouse is divided into zones and each picker is responsible for their own zone. Orders are passed from zone to zone until they are complete. This system reduces the number of trips per picker but requires good coordination between zones to avoid delays.

The choice between these methods depends on the order volume, the average order size, and the available technology. For many warehouses, a hybrid approach—using batch picking for standard orders and single-order picking for exceptions—is the most practical solution.

What tools help reduce time wasted during order picking?

The most effective tools for reducing time wasted during order picking are systems that minimize movement, prevent errors, and speed up physical tasks. Examples include pick-to-light systems, mobile scanners, ergonomic transport equipment, and optimized picking carts. The right combination depends on the type of goods and the scale of the picking process.

Specifically, the following tools make a measurable difference:

• Pick-to-light and put-to-light: visual indicators on the racks that guide the picker directly to the correct location and significantly reduce errors.
• Barcode and RFID scanners: speed up the verification of picked items and prevent errors from being discovered only during packaging.
• Ergonomic pallet trucks and mobile lifters: reduce physical strain when moving heavy goods and increase the speed per operation. For applications such as box handling or bag handling, there are specific solutions designed to reduce the strain on the picker.
• Warehouse Management Systems (WMS): automatically optimize the order of picking lists based on the warehouse layout, so that each route is as short as possible.
• Multi-compartment picking carts: make batch picking practical without items getting mixed up.

Choosing the right material handling products is not just a matter of speed, but also of ergonomics. Pickers who exert less physical effort make fewer mistakes and maintain productivity even at the end of a shift.

How can you objectively measure time wasted in a picking process?

You can objectively measure time wasted in a picking process by breaking down the picking time per order into sub-tasks and recording each step separately. The most commonly used method is a time study in which an observer or a digital system tracks how much time a picker spends moving, searching, picking, checking, and waiting.

Without measurement, it is impossible to know which step causes the most loss. A warehouse that suspects that movement is the bottleneck may discover, after conducting a time study, that search time and error correction together have an equally significant impact.

Practical methods for measuring time wasted:

1. Time study by step: Record how much time each sub-task takes for a representative number of orders. This can be done manually or through a WMS with time-tracking capabilities.
2. Distance Measurement: Use floor tracking or pedometers to track the average walking distance per order. A high walking distance per order is a direct indicator of a suboptimal layout.
3. Error Tracking: Keep track of how many picking errors are made per day or per picker, and calculate the correction time associated with them.
4. Comparison with the standard: Set a realistic standard picking time for each order type and compare it with actual performance. Deviations above the standard are measurable sources of wasted time.

Anyone seeking a systematic understanding of the efficiency of their picking process can also have an external workstation analysis conducted. Such an analysis not only identifies time wastage but also pinpoints ergonomic issues that indirectly reduce productivity.

How Logitrans Handling Helps Improve Order Picking Efficiency

Time wasted during order picking often stems from multiple causes at once: a suboptimal layout, unsuitable tools, and physically demanding tasks that undermine pickers’ speed and accuracy. We offer concrete solutions that address each of these bottlenecks.

• Free workstation analysis: Our specialists will analyze your picking process on the shop floor and identify where the most time is lost.
• Ergonomic material handling equipment: from pallet trucks to mobile lifters, we provide tools that help pickers work faster and more safely.
• Customized solutions: Based on your material flows and warehouse layout, we recommend the combination of products and systems that will deliver the highest return on investment.
• Showroom in Drongen: Test the solutions with your own materials before making a decision, so you can be sure you’re making the right choice.
• Maintenance Contracts: We ensure that your material-handling equipment remains in top condition, so your picking process is never interrupted by a malfunctioning machine.

Would you like to know where your picking process is losing time and money? Contact us for a no-obligation consultation or a free workstation analysis.

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