Order-picking speed is slow, despite having a good team, because the problem rarely lies with the employees themselves. Physical strain, inefficient warehouse layout, and a lack of tools all contribute to hidden time losses that accumulate throughout the workday. This article answers the most frequently asked questions about picking speed and shows where time is actually being lost.
What slows down the order-picking process on the shop floor?
The order-picking process is slowed down primarily by a combination of unnecessary walking distances, physical fatigue, and unclear workflows. Even experienced employees lose time when the workspace isn’t tailored to the tasks they need to perform. The cause is therefore structural, not personal.
In practice, there are four types of delays that occur repeatedly in warehouses:
- Unnecessary travel: Pickers have to walk long distances because products are not logically organized based on picking frequency or order profile.
- Waiting times: Employees wait for a pallet truck, an elevator, or a coworker who is blocking the same aisle.
- Repetitive tasks—such as stacking boxes, turning pallets over, or searching for products that have been stored incorrectly—take several minutes per order.
- Physical exhaustion: As the day goes on, the pace slows due to the cumulative strain on the body.
What these factors have in common is that they are rarely recognized as a problem. They are considered a normal part of the job. Yet it is precisely this normalization that structurally undermines warehouse productivity.
How does physical strain affect the work pace of pickers?
Physical strain reduces order-picking speed in two ways: directly, by slowing down heavy tasks, and indirectly, through fatigue that builds up over the course of the shift. A picker who is still working efficiently in the morning performs measurably slower by the end of a shift due to cumulative muscle fatigue and reduced concentration.
Lifting, bending, twisting, and pushing are the most physically demanding tasks involved in pallet handling and order picking. Each task on its own may seem manageable, but repeating them hundreds of times a day takes its toll. The body compensates by moving more slowly, taking more breaks, or performing tasks with less precision.
In addition, physical strain has an indirect effect on picking efficiency through absenteeism due to illness. Employees with back or joint problems are more likely to be absent, which places an extra burden on the remaining staff and further slows down the pace of work. This creates a negative spiral that is difficult to break without a structural approach to ergonomics in the workplace.
Here’s a concrete example: a picker who has to pick up boxes from a low pallet bends over dozens of times per hour on average. When this is replaced by a workstation at the proper working height, the physical strain decreases dramatically and the pace remains more stable throughout the entire shift.
Less effort, more performance
Lift more efficiently with ergonomic lifting solutions. Our specialists are happy to work with you to find the right solution.
What role does warehouse layout play in slow order picking?
Warehouse layout is one of the biggest yet least obvious causes of slow order-picking speeds. A poorly laid-out warehouse forces pickers to take long walking routes, make unnecessary changes in direction, and waste time searching for products. Even small improvements to the layout can significantly increase picking speed.
The most common layout mistakes that slow down picking are:
- Fast-moving items are too far from the shipping depot: the products that are picked most often should be located closest to the exit or the packing station.
- Aisles are too narrow for material-handling equipment: when a pallet truck or mobile lift cannot fit through the aisle, it is not used, and the physical strain increases.
- Picking locations are outside the ergonomic reach: products stored too high or too low require more time and energy per pick.
- Illogical product grouping: Orders containing multiple related products require unnecessary detours when those products are scattered throughout the store.
The layout of the warehouse also determines the extent to which ergonomic aids can be used effectively. An aid that does not fit into the workflow or the space will not be used. The layout and equipment must therefore be coordinated.
When Are Ergonomic Aids the Solution to Slow Picking?
Ergonomic aids are the right solution when slow order-picking speeds are directly linked to physical tasks that slow down or exhaust employees. If pickers regularly lift heavy loads, have to reach awkwardly, or repeatedly bend over, then ergonomic aids are not a luxury but an investment in productivity.
Choosing the right tool depends on the type of task and the material being picked. Different solutions are available for handling boxes than for moving pallets or lifting heavy sheets. It is therefore important to identify the specific tasks before making a decision.
Ergonomic aids increase picking speed in three ways:
- They reduce handling time: a vacuum lifter picks up a box faster than an employee who lifts and rotates it manually.
- They reduce fatigue: less physical effort per task means that the pace remains more consistent throughout the entire shift.
- They enable flexible deployment: employees can perform a wider variety of tasks without the risk of becoming overburdened, which simplifies scheduling.
However, tools are not a solution when the problem lies elsewhere—for example, in a poor layout or unclear picking lists. They enhance a good workflow, but they do not replace it.
How do you determine exactly where the order-picking pace is slowing down?
You can identify where order-picking speed is lost by breaking down the picking process into measurable sub-activities and tracking them separately. Consider walking time, search time, handling time, and wait time per order. Only when you know which part takes the most time can you take targeted action to improve picking efficiency.
A practical approach consists of the following steps:
- Time tracking by activity: Have pickers or an observer track how much time each sub-activity takes during a representative shift.
- Walking Route Analysis: Determine how many meters a picker walks per order and compare that to the theoretically shortest route.
- Morning vs. Afternoon Comparison: Measure your pace at the beginning and end of a shift to identify the effects of fatigue.
- Analysis of errors and rework: Count how many picks are repeated due to errors, searching, or incorrect locations.
A workstation analysis is a structured method for gathering this information without having to measure everything yourself. A specialist observes the workplace and identifies both the physical demands and the process bottlenecks. This provides a much more complete picture than statistics alone.
How Logitrans Handling Helps Improve Order-Picking Speed
Logitrans Handling offers a practical approach for warehouses struggling with slow order-picking speeds. We combine expertise in ergonomics, material handling, and workflow optimization to systematically improve picking efficiency. Our approach includes:
- Free Workstation Analysis: A specialist analyzes the workstation, the tasks performed, and the challenges on the job site.
- Customized solutions: Depending on the type of task, we recommend the most suitable ergonomic aid, ranging from vacuum lifters to pallet trucks and mobile lifters.
- Testing in the demo room: In our demo room in Drongen, employees can try out the solutions using their own materials, so that their choice is based on real-world experience.
- Support from A to Z: from consulting and implementation to user training and a maintenance contract for long-term reliability.
An investment in ergonomic equipment is also an investment in warehouse productivity, reduced absenteeism, and a more stable operation. Want to know exactly where your order-picking speed is falling short? Contact us for a free workstation analysis and discover which solution best fits your situation.
Less effort, more performance
Lift more efficiently with ergonomic lifting solutions. Our specialists are happy to work with you to find the right solution.
