The warehouse is a bustling maze loaded with inventory wherein pickers must go on an adventurous treasure hunt to find the customer’s order. Navigating through each shelf for a particular order is very hectic on the part of pickers and also reduces their efficiency. This is why wave picking is considered as the efficient way in the warehouse and its operations.
With tons of order-picking methods in the industry, wave picking stands out from its competitors. But what is the wave-picking method? How is it different from the age-old batch picking? What are its advantages and disadvantages?
Let’s explore these questions in this blog post!
What Is Wave Picking?
Wave picking is an order-picking method wherein the entire inventory is categorized into waves based on similarities, and pickers are assigned to collect the waves from their locations rather than collecting each order individually. A wave consists of a group of orders based on criteria such as product type, availability, shipping times, due date, etc.
It’s also known as cluster picking, as the picker doesn’t waste time and effort picking up every order. Rather, he picks up a batch of orders at one go. It’s a type of short interval scheduling (SIS) and is proven to be the most efficient among all the order-picking methods.
Wave picking order picking method comes in two variations:
- Fixed: In this method, the wave of orders is sent for packing all at once after being picked. All the orders must be picked before they are sent to be packed.
- Dynamic: In this method, an order from a wave is sent for packing right after being picked. One picked order wouldn’t hold back from being packed because of other orders in the wave.
How Does Wave Picking Work?
Wave picking may sound simple but is actually a bit complex. It’s because it requires the continuous collaboration of multiple roles to complete the order.
However, we can understand the entire process within 3 simple steps.
- Pre: It’s the first step wherein all the waves are formed and organized based on some specific variables. The orders are grouped together to form waves that the picker must pick up later. It’s the planning step of the entire wave-picking process. Although it sounds quite cumbersome, it becomes a lot easier with a warehouse management system which basically does the laborious task of making waves.
- Performing: In this process, pickers are assigned a wave. With hand-held scanners to help them know more about what and how much to pick, they set off to collect the items for that wave. This way, they are able to complete multiple orders simultaneously.
- Post: When all the orders are picked, they are sorted and again put into their scheduling waves for shipment.
How Does Wave Picking Differ from Batch Picking?
You must have come across the most common order-picking method, batch picking. Did your mind question how it is different? Here you go!
While batch picking involves a picker picking items from one part of the warehouse irrespective of their similarity, wave picking involves picking items listed in the wave only. Pickers in batch picking have just one task window throughout their entire shift. Whereas in this picking, pickers have multiple windows within a single shift.
In batch picking, the picker visits the inventory locations only once. This reduces the traffic, congestion and the chances of accidents. On the contrary, the pickers must visit the same location multiple times in this picking, thus putting the SKU at risk. Moreover, batch picking is ideal for businesses with small warehouses while other picking is perfect for large businesses and warehouses.
Advantages of Wave Picking
Are you wondering about the advantages? Read on & explore!
1. On-Time Shipments and Deliveries
Everything from categorizing orders into waves to shipping the waves is pre-planned in wave packing. This reduces the hustle for shipping, thus promising on-time shipping and deliveries.
2. Ideal for Fresh or High-Security Goods
Fresh goods, such as food items, spoil quickly. In this picking, items with a close expiry date can be put together in a wave and shipped. This prevents wastage of such inventory. Similarly, high-security items requiring special care can be grouped together and processed. This eliminated the hassle of shipping each item with care.
3. Optimizes the Picking Process
In wave picking, pickers don’t need to travel to multiple locations multiple times to collect items. Instead, they pick a wave containing all the orders with similar attributes. This optimises the picking process, thus reducing the travel time and time wastage.
4. Improved Efficiency
As the items are already grouped in waves, the picker doesn’t need to spend time sorting and categorizing them. This not just saves time but also improves the efficiency of the pickers accurately. thus allowing them to complete multiple orders all at once.
5. Improved Productivity
Wave picking reduces the need for pickers to take regular trips to different warehouse locations to pick up the orders. Moreover, it lets pickers complete many orders simultaneously, ultimately improving their productivity.
6. Reduction in Errors and Bottlenecks
Wave picking is a cohesive approach wherein pickers focus on a specific group of products at once. It streamlined the process, reducing congestion and confusion caused in the aisles due to batch picking and other such methods. This ultimately reduces errors and bottlenecks in the picking process, thus fostering a smooth workflow.
7. Cost Effective
Wave picking reduces the need for human labor and helps you optimize your resource allocation. It’s a cost-effective approach as it reduces the travel costs of pickers, chances of product wastage, etc.
Do you want to integrate advanced business solutions into your business? Worry not because we bring you QodeNEXT and its unique solutions tailored to meet your unique needs. It has a comprehensive suite of hardware and software solutions which will take your business’s productivity and efficiency to the next level. Go check out QodeNEXT’s services now!
Disadvantages of Wave Picking
Despite the advantages, this picking method also comes with some disadvantages. Let’s have a look at them.
1. Complex
Implementing an order picking method within a warehouse is quite complex. Firstly, managers and other stakeholders must plan it carefully. Moreover, it also demands constant coordination. The toughest part is training the employees. Thus, it leads to a steeper learning curve, so it’s not ideal for small warehouses.
2. Risks of Downtime
Another noteworthy disadvantage of implementing the wave-picking method is the high risk of downtime. While the waves increase the efficiency of pickers, it also leads them to face idle hours between waves. Moreover, other unforeseen delays and disruptions can also impact the flow of goods, thus increasing the risks of downtime.
3. Increased Setup Time
Setting up the entire process within a warehouse requires planning, time, and meticulous attention to detail. Small mistakes can wreak havoc on the entire supply chain.
4. Limited Flexibility
The orders are batched in waves, which makes it difficult to make changes at crucial times. This inflexibility is a major con for warehouses that are prone to urgent adjustments and last-minute modifications.
Wrapping Up
The wave picking method stands out among all other order-picking methods. It’s because it’s organized, improves order consolidation, and is highly scalable. It also improves efficiency and productivity of the pickers and the entire supply chain while offering cost-saving benefits too. Before implementing this method, make sure to analyze if your business really needs it.
If you need any help or assistance, check out our indispensable solution, QodeNEXT. Please feel free to contact us now to help you make the best choice to manage your fleet and optimize your process!
FAQs: Wave Picking in Warehouse Management
1. What is wave picking in warehouse management?
Wave picking is an order fulfillment strategy where similar orders are grouped into “waves” based on factors like delivery schedule, product type, or shipping carrier. It helps streamline the picking process and improve overall efficiency.
2. How does wave picking work?
In wave picking, warehouse staff receive grouped orders to pick during specific time slots or “waves.” Each wave is scheduled based on order priorities, allowing smoother coordination between picking, packing, and shipping.
3. What are the main benefits of wave picking?
Wave picking helps reduce travel time, improves order accuracy, balances workload across teams, and enhances coordination between warehouse departments.
4. How is wave picking different from batch picking or zone picking?
- Batch Picking: Workers pick multiple orders at once to reduce travel time.
- Zone Picking: Workers pick items only from their assigned zones.
- Wave Picking: Combines both methods—grouping orders by priority and timing to synchronize picking and shipping efficiently.
5. When should a warehouse use wave picking?
Wave picking works best in medium to large warehouses handling high order volumes, especially those with scheduled shipping or multiple carrier cut-off times.
6. What types of businesses benefit most from wave picking?
E-commerce companies, 3PL providers, and manufacturers with frequent, time-sensitive shipments benefit the most from implementing wave picking.
7. What technology supports wave picking?
Warehouse Management Systems (WMS) play a critical role. They automatically group orders into waves, optimize pick paths, and assign tasks to warehouse workers.
8. How can wave picking improve order accuracy?
By organizing orders and assigning clear picking instructions, wave picking minimizes confusion and ensures that each item is picked correctly and on time.
9. Can wave picking be combined with automation?
Yes. Wave picking can be enhanced with automated picking systems, conveyor belts, and robotics to speed up operations and reduce manual errors.
10. What are the main challenges of wave picking?
Challenges include complex scheduling, dependency on accurate inventory data, and the need for well-trained staff to manage multiple waves efficiently.
11. How does wave picking affect warehouse productivity?
It boosts productivity by grouping tasks logically, reducing downtime between waves, and allowing warehouse teams to focus on specific batches of work.
12. How do you schedule waves effectively?
Schedule waves based on shipping priorities, carrier cut-off times, product categories, or warehouse zones. A WMS can automate this process for maximum efficiency.
13. What metrics should be tracked for wave picking performance?
Monitor order accuracy, picking time per wave, labor utilization, and on-time shipment rate to measure wave picking success.
14. How do you train staff for wave picking?
Provide training on WMS usage, order prioritization, and pick-path optimization. Clear communication between departments is also key to effective wave execution.
15. Is wave picking suitable for small warehouses?
Small warehouses with limited SKUs or low order volumes may not need wave picking. However, they can still apply simplified versions, like batching similar orders together, to save time.
