Why does my order-picking process get bogged down during peak periods?

The order-picking process grinds to a halt during peak periods because the combination of higher volumes, time pressure, and limited resources exposes bottlenecks that are barely noticeable on normal workdays. Warehouses that run smoothly on quiet days run into problems with routing, ergonomics, and material availability during peak periods. This article answers the most frequently asked questions about why order picking breaks down under pressure and what you can do about it.

What bottlenecks slow down order picking the most?

The biggest bottlenecks in the order-picking process are inefficient walking routes, unclear item locations, insufficient or poorly maintained handling equipment, and physical fatigue among employees. These factors reinforce one another: employees who walk too far tire more quickly and make more mistakes, which further increases the turnaround time per order.

Specifically, these are the most common bottlenecks in a warehouse:

• Poor pick routing: Employees have to walk the same routes multiple times because orders are not assembled in an optimized manner.
• Incomplete or incorrect location information: Searching for an item takes time that isn't productive.
• Waiting for equipment: Not having enough pallet trucks or lifters means that employees have to wait for each other, especially during periods of high volume.
• Manual tasks without assistive devices: Lifting and moving heavy loads without ergonomic support not only slows down the process but also increases the risk of errors and injuries.
• Communication breakdowns: Uncertainty about priorities or order status leads to duplicate work or missed picks.

Many of these bottlenecks are structural in nature. They become apparent during peak periods, but their root cause lies in how the warehouse is organized on normal days. Efficient pallet handling is an underestimated factor in this regard: the faster pallets are moved and positioned, the less wait time there is in the picking flow.

Why are peak periods so different from normal workdays?

Peak periods differ fundamentally from normal workdays because volume increases while infrastructure, staffing, and processes remain the same. That discrepancy exposes every weak link in the warehouse. What is a minor inefficiency on a slow day becomes a real bottleneck during a peak.

During peak periods, several factors come into play at the same time:

• Having more employees in the same floor space leads to conflicts regarding walking routes and the use of equipment.
• Temporary workers are less familiar with the warehouse layout and are more likely to make mistakes or take inefficient routes.
• Higher pressure per employee leads to rushing, which increases the risk of incidents and picking errors.
• Material shortages are becoming more acute: on a normal day, the absence of a single pallet truck can be managed, but during a peak period, it has an immediate impact on lead time.

So the difference lies not only in the volume, but in the way systems and people respond to that extra pressure. Warehouses that continue to function well during peak periods have tailored their processes and equipment in advance to handle that higher workload—not just the daily average.

How does ergonomics affect the speed of order pickers?

Ergonomics has a direct impact on the speed of order pickers: employees who experience less physical strain are able to maintain a consistent work pace for longer and make fewer errors due to fatigue. An ergonomic warehouse is therefore not only healthier, but also demonstrably more productive, especially as the workday or peak period progresses.

The relationship between ergonomics and speed operates on two levels:

Short term: fatigue and errors

An order picker who repeatedly lifts heavy boxes without any aids will noticeably slow down after a few hours. Concentration wanes, movements become less precise, and the likelihood of picking errors increases. Every error that needs to be corrected costs extra time and puts additional pressure on the rest of the team.

Long term: absenteeism and staff shortages

In the long term, non-ergonomic working conditions lead to back pain, shoulder problems, and other physical ailments. This results in absenteeism, which is particularly problematic during peak periods. An employee who is absent during the busiest time of the year places a disproportionate burden on the rest of the team. Investing in ergonomic work practices is therefore also a form of risk management for your workforce.

Which handling solutions reduce pressure during peak periods?

The most effective material-handling solutions during peak periods are those that take over or simplify repetitive, physically demanding tasks: ergonomic pallet trucks, mobile lifters, and semi-automatic systems for moving pallets. These tools increase individual output per employee while reducing physical strain.

Depending on the type of goods you handle, there are tailored solutions available:

• Pallet trucks and electric pallet trucks: They speed up the transport of full pallets through the warehouse and significantly reduce the distance order pickers have to walk.
• Mobile lifts: ideal for placing or retrieving goods at height without requiring employees to bend over or reach.
• Vacuum lifters: When handling boxes, sheets, or bags, vacuum lifters take over all the lifting work, which increases the speed of each operation.
• Semi-automatic pallet handling systems: For warehouses with high pallet volumes, automated systems can save a significant amount of time when swapping, rotating, or stacking pallets.

Browse the full product line to see which solutions are best suited to your specific situation. The right choice depends on the type of goods, the warehouse layout, and the frequency of operations.

When is a job analysis useful for your warehouse?

A job analysis is worthwhile as soon as you notice that certain tasks consistently take a long time, employees are complaining about physical strain, or your warehouse efficiency isn’t keeping pace with demand. You don’t have to wait for an incident or a peak period to have this investigated, because taking preventive action is always less expensive than reactive remediation.

Specific signs indicating the need for a job analysis:

• Repeated absences due to back pain or other physical ailments among warehouse staff.
• Bottlenecks that occur repeatedly at the same workstation or during the same type of operation.
• Temporary employees who have trouble keeping up with the pace of work.
• Outdated or inadequate equipment that no longer meets the current volume or flow of goods.
• Plans to expand or renovate the warehouse with the goal of optimizing the layout.

A thorough analysis of the workstation provides insight into which tasks take the most time and energy, and where targeted investments yield the greatest return. This also makes it easier to set priorities when purchasing new equipment.

How Logitrans Handling Helps When the Order-Picking Process Gets Stuck

We guide warehouses from start to finish in identifying and resolving bottlenecks in the order-picking process. Drawing on our expertise in ergonomic material handling, we offer concrete solutions that both reduce the workload and increase warehouse efficiency, especially during peak periods.

Here's what we do for you, specifically:

• Free workplace analysis: Our specialists will visit your site to assess your current situation and identify any issues.
• Customized solutions: Whether you need pallet trucks, vacuum lifters, or semi-automatic systems, we’ll recommend the equipment that best suits your specific material flow and workstation.
• Showroom in Drongen: You can test out any solution with your own materials before making a decision.
• Maintenance and Service: Through a maintenance contract, we ensure that your material-handling equipment is always in top condition, even during the busiest time of the year.
• Training upon installation: We ensure that your employees use the new equipment correctly and safely from day one.

Is your order-picking process stalling, and do you want to know what the real cause is? Contact us for a no-obligation consultation or a free workstation analysis.

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