Picking Strategies
Order-Oriented Sequential Picking
How to Optimize Your ProcessesAs fast as possible or as error-free as possible? When selecting the right picking strategy, speed and accuracy often compete with one another. This is especially true when processes are not yet fully automated and human involvement remains essential. In any case, it is worthwhile to carefully evaluate the advantages and disadvantages of different picking methods. After all, picking is one of the most cost-intensive and error-prone processes in a warehouse. Studies show that it can account for up to 50% of total warehouse costs.
One proven yet often misunderstood method is order-oriented sequential picking. When implemented correctly, it creates transparency, reduces errors, and stabilizes throughput times—particularly in environments with high product variety and clearly structured orders.Â
One Order at a Time
In order-oriented sequential picking, each customer order is processed completely and consecutively. A picker (or an automated system) collects all items belonging to a single order before the next order is started. The order therefore moves sequentially through the picking process.
The focus is clearly on the individual order—unlike batch-oriented or series-oriented methods, where multiple orders or item groups are processed simultaneously. This makes the method particularly transparent and easy to follow.
Picking Strategies Compared:
Choosing the Right MethodOne order after another, high transparency, simple control.
Item-based picking for multiple orders, followed by later sorting.
Multiple orders at the same time, higher efficiency for large numbers of small items.
Orders pass through multiple warehouse zones, often combined with conveyor technology.
Distinguishing It from
Other Picking Strategies
To properly assess the strengths and weaknesses of order-oriented sequential picking, it helps to compare it with other methods. In sequential, order-oriented picking, one order is completed before the next one begins. This creates a high level of transparency and makes the process easy to manage.
In contrast, sequential, item-oriented picking processes multiple orders in parallel. Individual items are picked for several orders and sorted afterward.
Alternative Picking Methods
In parallel picking, several orders are processed simultaneously. The picker fills different order containers located on a picking cart. This approach is particularly efficient when handling many small items.
Another strategy is zone picking. Here, orders pass through several warehouse zones, which can be managed by different employees. This picking method is often combined with conveyor systems.
Where Sequential Picking Shows Its Strengths
Applications in the WarehouseOrder-oriented sequential picking is particularly useful when order clarity, process reliability, and low error rates are more important than achieving maximum picking performance per hour.
Typical Applications of
Order-Oriented Sequential Picking:Â
- Warehouses with low to medium order frequency
- High product variety with a manageable number of order lines
- Project-based or customer-specific orders
- Spare parts and service logistics
- B2B operations with clearly defined delivery deadlines
- Highly automated warehouses
Order-oriented sequential picking is commonly found in warehouses with low to medium order volumes. Another typical characteristic—regardless of the other criteria—is high product variety combined with a manageable number of positions per order.
Sequential, order-based picking is also used for project-related or customer-specific orders. The same applies to spare parts and service logistics, as well as B2B operations with clearly defined delivery dates, where picking errors would result in high follow-up costs.
Even in automated warehouses—such as shuttle systems, AutoStore installations, or high-bay pallet warehouses—sequential order processing is often chosen to keep orders clearly separated and easy to track.Â
Benefits of Order-Oriented Sequential Picking
When implemented correctly, this method offers a range of compelling advantages. One key benefit is the high level of transparency. Each order can be uniquely identified at any time. Status, progress, and any deviations can be easily tracked—an important advantage for management, customer service, and quality assurance.
Another advantage is the low error rate, especially in manual environments. Since orders are not mixed, the risk of misallocations is significantly reduced. This is particularly important when handling critical or high-value items. The method also stands out because of its simplicity. The logic is easy to understand and straightforward to learn. This reduces training efforts and makes the process more resilient to staff changes or seasonal fluctuations.
Finally, order-oriented sequential picking is highly predictable. Clearly defined order flows allow throughput times to be planned more reliably—an advantage when strict delivery commitments must be met.Â
Benefits at a Glance:
- Maximum transparency
- Low error rate
- Simple processes
- Reliable planning
Disadvantages:
- Longer travel distances for many small orders
- Fewer economies of scale compared to batch or zone picking
- Limited productivity at very high order frequencies
Limitations and Challenges
Despite its advantages, order-oriented sequential picking is not the best choice for every scenario. For many small orders, longer travel distances become a significant factor. Compared to batch or zone picking strategies, this method also benefits less from economies of scale.
Especially in environments with very high order volumes, order-oriented sequential picking offers only limited productivity.
However, these disadvantages can often be reduced through targeted optimization measures.
Process Optimization
Getting the Most Out of ItOne important lever is intelligent order sequencing. Even in sequential picking, orders should not be processed randomly. Optimized sequencing can reduce unnecessary travel distances.
Another area for improvement is ergonomic warehouse design. Short reaching distances, clear labeling, and ergonomically arranged picking locations all contribute directly to efficiency—especially for single-order picking.
Optimization Potential
in Order-Oriented Sequential Picking:Â
- Intelligent order sequencing
- Ergonomic warehouse design
- Intelligent warehouse management software
- Combination with automation
- Clear interfaces to packing and shipping
A modern Warehouse Management System (WMS) is indispensable. The software should be able to prioritize orders, provide picking dialogs, and display status and progress in real time.
In addition, order-oriented sequential picking can be combined with automation at any time. Sequential picking does not exclude automation. On the contrary, in automated warehouses, order-based item provisioning can simplify processes—for example through goods-to-person concepts.
Further optimization potential lies in creating seamless interfaces to packing and shipping. Once orders are fully picked, packing, labeling, and shipping should follow efficiently. Media disruptions should be avoided wherever possible.
The Role of the Warehouse Management System
The WMS is the central control system for order-oriented sequential picking. Modern systems enable dynamic prioritization of orders and transparent order tracking.
The integration of mobile data capture devices as well as Pick-by-Voice and Pick-by-Light solutions should also be easily supported. Process changes must be manageable without major effort. Especially in sequential processes, software flexibility and modularity are essential.
Requirements for
the Warehouse Management System:
- Dynamic order prioritization
- Easy software adaptation to process changes
- Transparent order tracking
- Integration of MDE devices, Pick-by-Voice, and Pick-by-Light solutions
pLG Warehouse Management System
Benefit from pLG SolutionsReduce inventory discrepancies sustainably: With real-time postings, guided workflows, and transparent inventory management, the pLG WMS ensures reliable inventory data—and therefore higher delivery performance, less rework, and more predictable operations.
Conclusion
Order-oriented sequential picking is not an outdated model but a deliberate organizational principle that provides clarity, quality, and process reliability. It is particularly suitable for companies that value transparent workflows, low error rates, and stable throughput times.
Organizations that combine this method with intelligent IT support, thoughtful warehouse design, and targeted automation can largely offset its perceived efficiency disadvantages. Ultimately, success depends not on the method itself, but on how consistently it is adapted to the company’s specific requirements.
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