Warehouse & logistics
Order Picking
By the Supply Chain Manager team · Updated October 16, 2026
Order picking is collecting the items for customer orders from their storage locations, usually the most labor-intensive job in a distribution warehouse.
Common methods are discrete picking (one order at a time), batch picking (several orders at once, sorted afterwards), zone picking (each picker covers an area) and wave picking (orders released in timed groups to match shipping cut-offs).
Method choice depends on order profile. Many small orders with few lines suit batch picking; a few large orders suit discrete picking; large warehouses with many zones suit zone or wave picking. Many distribution centers mix methods, using batch picking for small parcels and discrete picking for pallet orders.
How to calculate order picking
Pick Accuracy % = Order lines picked correctly ÷ Order lines picked × 100
Order picking example
Illustrative: a warehouse picking 1,200 small orders a day switches from discrete to batch picking for orders under five lines. Walking distance falls because each trip serves many orders, then items are sorted by order at a packing station.
Why order picking matters for distributors
Picking speed and accuracy decide whether orders leave the same day and arrive complete. Mis-picks also corrupt inventory records: the wrong SKU leaves, and both counts go wrong.
Common order picking mistakes
- Keeping fast movers in far corners, which multiplies walking time.
- Picking without scanning, so errors are found only by the customer.
Examples on this page use made-up round numbers to show the calculation. They are not benchmarks or results from real businesses.