What are the most common causes of slow order picking?

Slow order picking usually has multiple causes at the same time: an inefficient warehouse layout, poor ergonomics, outdated technology, and avoidable picking errors constantly reinforce one another. Together, they result in longer cycle times, more errors, and higher operating costs. In this article, we answer the most frequently asked questions about the causes of slow order picking and what can be done about it.

Which warehouse layout slows down order picking the most?

A warehouse layout slows down order picking the most when popular items are located far from the shipping zones, aisles are too narrow for smooth driving or walking, and products are stored randomly without logical grouping. Pickers then have to cover unnecessary distances for each order, which directly reduces order-picking efficiency.

The layout of a warehouse largely determines how quickly pickers can complete their routes. A common mistake is storing items based on available space rather than on picking frequency. Items that are picked daily should be located as close as possible to the shipping zones. Items that are rarely requested can be stored farther away.

In addition, pallet handling plays a major role. When pallets are not positioned correctly or are difficult to reach, a picker loses valuable time at every stop. A well-thought-out ABC layout, in which A-items are the most accessible, is a proven method for systematically reducing walking times.

• Place A-items (high-turnover items) as close as possible to the shipping zones
• Keep aisles wide enough to allow for the smooth operation of material-handling equipment
• Logically group product categories to make combined orders more efficient
• Use clear signage and location codes to eliminate search time

How does poor ergonomics affect picking speed?

Poor ergonomics slow down order picking because pickers have to exert more physical effort with every action. Uncomfortable lifting and twisting positions, excessive force required to move goods, and repetitive movements lead to fatigue, which causes a noticeable drop in work speed after just a few hours.

A picker who has to repeatedly lift heavy boxes or bags by hand slows down as the shift progresses. This is not only a safety issue but also a productivity issue. Back pain and muscle soreness are common complaints in warehouses where ergonomics is not a priority, and they lead to absenteeism that puts further pressure on planning capacity.

Ergonomic work goes beyond maintaining good posture. It also means having the right tools available so that pickers can move goods without exerting excessive force. When box handling or the movement of heavy loads is supported by the right lifting aids, work speed remains consistent throughout the entire shift.

What are the consequences of outdated or missing picking technology?

Outdated or missing picking technology forces employees to rely on manual processes that are error-prone and time-consuming. Without digital support such as barcode scanners, pick-by-light, or a robust WMS, pickers have to search, check, and correct more often, which directly slows down order picking.

Paper picking lists are a classic example of a technological bottleneck. They are static, offer no real-time feedback, and do not indicate when a location is empty or a product has been moved. Pickers are then faced with surprises in the middle of their route, leading to delays and frustration.

Modern picking technology solves this by guiding pickers step by step, automatically adjusting priorities, and immediately flagging errors. However, technology alone is not enough: the physical equipment used to move goods also plays a role in determining how quickly an order can be completed. View the complete overview of available products that can support the picking process.

• Replacing paper-based lists with digital scanning or voice systems
• Implementing a WMS that provides real-time location and inventory information
• Keep physical handling equipment up to date so that goods can be moved quickly and safely
• Regularly assess whether the current tools still meet the picking volume

Why do picking errors cause additional delays?

Picking errors cause additional delays because they not only result in the error itself but also trigger a correction process. An incorrectly picked item must be returned to its proper location, the correct location must be located, and the order must be repicked, which significantly increases the total processing time.

Errors in the picking process have a ripple effect. An error that isn’t discovered until the packaging stage—or even at the customer’s location—takes exponentially more time to resolve than one that is identified immediately. Return processing, customer communication, and redelivery are time-consuming processes that systematically undermine warehouse productivity.

The most common causes of picking errors in the warehouse are unclear product labels, incorrect storage locations, picker fatigue, and a lack of double-checking. A combination of clear location markings, ergonomically designed workstations, and supportive technology significantly reduces the error rate. Fewer errors mean less rework and, therefore, a higher net picking speed.

How can semi-automation and handling equipment speed up order picking?

Semi-automation and handling equipment speed up order picking by reducing the physical strain of repetitive tasks and shortening the turnaround time per order. Pickers can focus on the actual picking work while machines handle the moving, turning, or positioning of goods and pallets.

Pallet trucks, mobile lifters, and electric tow tractors are examples of equipment that can drastically reduce the time required per operation. Whereas an employee without such equipment might need several minutes to move a heavy pallet, with the right machine, they can do so in a fraction of the time. That difference adds up over hundreds of operations per day.

Semi-automation takes things a step further: think of pallet trucks with automated functions or systems that automatically swap and position pallets. These solutions are particularly valuable in warehouses with high picking volumes, where every second gained per operation translates into significant time savings on a daily basis. Also explore the options for specific applications based on the type of goods.

How Logitrans Handling Helps Optimize Order Picking

At Logitrans Handling, we combine ergonomic expertise with a wide range of handling equipment to effectively address the most common causes of slow order picking. Whether it’s speeding up pallet handling, reducing physical strain, or implementing semi-automation, we offer customized solutions for every warehouse.

• Free Workstation Analysis: Our specialists will analyze your current picking process and identify the biggest bottlenecks
• Ergonomic lifting aids: from vacuum lifters to mobile lifters, tailored to your specific goods and workplace
• Semi-automation solutions: for time-consuming tasks such as moving and swapping pallets
• Demonstration Room in Drongen: Test our solutions with your own materials before you make a decision
• Maintenance Contracts: To Ensure Your Equipment Always Remains in Top Condition and Downtime Is Avoided

Would you like to know which approach will make the biggest difference in your warehouse? Feel free to contact our specialists for a no-obligation consultation.

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