Picklists play a vital role in ensuring orders are fulfilled accurately and efficiently in eCommerce and warehouse management. Whether you’re running a small business or managing a large-scale warehouse, understanding what a picklist is and how to use it can streamline your operations, reduce errors, and improve customer satisfaction. This article covers everything you need to know about picklists, including their definition, importance, creation, and examples of their use in warehouse management.
What Is a Picklist?
A picklist (also called a pick list) is a document that warehouse staff use to retrieve items from inventory. It contains essential details about the products to be picked, such as item names, quantities, locations within the warehouse, and stock-keeping units (SKUs). Picklists act as a bridge between the order placed by a customer and the fulfillment process in the warehouse.
For example, when an online order is placed, a picklist is generated for warehouse staff. It outlines the exact items they need to “pick” from shelves to fulfill that order.
In simple terms, a picklist is like a shopping list for warehouse workers. It tells them:
- What items to pick (product names and descriptions).
- How many of each item to pick (quantities).
- Where to find these items in the warehouse (product location).
Why Are Picklists Important?
Picklists are essential for any business involved in product storage and order fulfillment. They bring organization and accuracy to the picking process, which is the cornerstone of efficient warehouse operations. Here’s why picklists are so important:
1. Accuracy in Order Fulfillment
Picklists reduce the chances of picking the wrong items, ensuring customers receive exactly what they ordered. Accurate orders translate to happy customers and fewer returns or complaints.
2. Increased Efficiency
By organizing the picking process, picklists save time for warehouse staff. Instead of guessing or searching aimlessly, workers know exactly where to find the required items.
3. Reduced Errors
Assigning specific picklists to individual staff members minimizes mistakes during fulfillment. This is especially useful in warehouses with a large inventory or high order volumes.
4. Improved Productivity
Clear and concise picklists keep the workflow smooth and efficient. Employees can complete tasks faster and focus on fulfilling more orders.
5. Scalability
For businesses experiencing growth, picklists make it easier to scale operations. With an organized picking process, handling a higher volume of orders becomes manageable.
What are the Types of Picklists?
Picklists come in different formats depending on the size and complexity of the business. The two main types are:
1. Physical Picklists
These are printed documents handed to warehouse pickers. They were commonly used before the advent of digital systems. While simple, physical picklists can be less efficient, especially for larger warehouses, as they do not provide real-time updates.
2. Digital Picklists
With advancements in technology, most businesses now use digital picklists. These are generated and managed using software or warehouse management systems (WMS). Digital picklists can be accessed on mobile devices, tablets, or computers, providing real-time updates and additional information such as product images.
Key Components of a Picklist
A picklist is a foundational tool for warehouse operations, guiding staff in retrieving items for order fulfillment. To ensure accuracy and efficiency, a picklist must include specific components tailored to the needs of the business and warehouse setup. Here are the key elements every picklist should have:
1. Order Number
The order number serves as a unique identifier for each picklist. It links the picklist to the customer order, helping to track the fulfillment process. In case of discrepancies or customer inquiries, the order number is used to resolve issues quickly. It ensures a seamless connection between picking, packing, and shipping stages.
2. Product SKUs
Stock-Keeping Units (SKUs) are essential for identifying products. Each SKU corresponds to a unique product variant, such as size, color, or model. Including SKUs in the picklist reduces the chances of errors, especially when similar products are stored together. Pickers can match the SKU on the picklist with the one on the product label for confirmation.
3. Product Location
The picklist must specify the exact location of each item in the warehouse, such as aisle, bin, or shelf numbers. Clear location details save time by minimizing the picker’s search efforts. Organized warehouses with labeled locations further enhance the effectiveness of this component.
4. Quantities
The quantity of each product required for the order is another critical detail. Precise quantities prevent under-picking or over-picking, ensuring that orders are fulfilled accurately and inventory levels remain consistent. This is particularly important for bulk or large-scale orders.
5. Product Descriptions or Images
To avoid confusion, picklists often include brief descriptions or images of the products. This is especially useful when items have similar appearances or names. Visual cues act as an extra layer of quality control for pickers.
6. Priority Level or Urgency
Some picklists may include indicators for time-sensitive orders. Highlighting such orders helps prioritize them, ensuring they are picked and shipped faster to meet customer expectations.
How to Create a Picklist
Creating a picklist can vary depending on the tools and systems you use. Below is a general guide on how to create a picklist:
Step 1: Process the Customer Order
When a customer places an order, the first step is to log it into your order management system (OMS) or warehouse management system (WMS). The system identifies the items, quantities, and shipping preferences associated with the order.
Step 2: Identify Required Items
Extract details of the products to be picked, including:
- Product name or description.
- SKU (Stock Keeping Unit) for precise identification.
- Quantity needed for the order. This information forms the basis of the picklist.
Step 3: Locate Products in the Warehouse
Determine the storage location of each item in the warehouse. Assign aisle numbers, bin locations, or shelf identifiers for easy retrieval. Clear and logical warehouse organization makes this step more efficient.
Step 4: Organize the Picklist
Arrange items on the picklist in a logical order to minimize picker movement. For example:
- Zone Picking: Group items by storage zones.
- Batch Picking: Combine similar orders for bulk picking.
- Pick-to-Order: List items in the sequence of customer orders.
Organizing the picklist based on warehouse layout can save significant time and effort.
Step 5: Format the Picklist
Design a clear and concise format for the picklist, including:
- Order number for reference.
- Item descriptions or product images.
- SKUs and quantities.
- Product location.
- Priority or urgency indicators, if applicable.
For manual systems, this picklist can be printed. For digital systems, it can be accessed on mobile devices or tablets.
Step 6: Assign the Picklist
Distribute the picklist to the appropriate warehouse picker. In large operations, multiple picklists may be assigned simultaneously to different staff members to improve productivity.
Step 7: Update and Track Progress
As items are picked, update the status of the picklist. This can be done manually by marking items as “picked” or digitally using barcode scanning. Tracking progress ensures that all items are picked accurately.
Example Picking List
Here’s a simple example of what a picklist might look like for a warehouse:
| Order Number | Product Name | SKU | Quantity | Location |
|---|---|---|---|---|
| 12345 | Red T-Shirt (M) | RT-M-001 | 3 | Aisle 2B |
| 12345 | Blue Jeans (L) | BJ-L-002 | 1 | Aisle 3C |
| 12345 | Black Shoes (10) | BS-10-003 | 2 | Aisle 5D |
This list provides the picker with all the necessary information to quickly locate and retrieve the items.
Common Picking Methods
The method used to pick items depends on the warehouse layout, staff availability, and order volume. Here are three common picking methods:
1. Pick-to-Order
- Definition: Each order is picked individually.
- Best For: Small businesses or warehouses with low order volumes.
- Example: A picker receives one picklist for one order and fulfills it before moving to the next.
2. Batch Picking
- Definition: Multiple orders are grouped together, and common items are picked in bulk.
- Best For: Large warehouses with high order volumes.
- Example: Picking 50 units of the same product for multiple orders simultaneously.
3. Zone Picking
- Definition: Pickers are assigned to specific zones within the warehouse.
- Best For: Warehouses with large layouts.
- Example: A picker retrieves all items from their assigned zone before passing the order to the next zone.
Challenges with Picklists
While picklists are invaluable, they come with certain challenges:
- Human Errors: Mistakes such as picking the wrong item or quantity can occur, especially when picklists are unclear or disorganized.
- Time-Consuming: Physical picklists require more time to distribute and update compared to digital picklists.
- Complexity in Large Warehouses: In large warehouses with thousands of SKUs, managing picklists efficiently can be challenging without the right tools.
- Technology Dependence: Digital picklists require investment in technology and training for staff.
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Optimizing Picklists for Efficiency
To make the most of your picklists, consider these tips:
- Use a WMS: A warehouse management system can automate the creation and tracking of picklists.
- Organize Inventory: Arrange products logically and label locations clearly.
- Train Staff: Ensure pickers are well-trained in using picklists and navigating the warehouse.
- Implement Barcode Scanning: Use barcodes to verify items during picking.
Final Thoughts
Picklists are the backbone of efficient warehouse management and order fulfillment. They ensure that the right items are picked, packed, and shipped to customers on time. Whether you’re using physical or digital picklists, understanding their components, methods, and optimization techniques can significantly improve your warehouse operations.
FAQs About Picklists
What is the difference between a picklist and a packing list?
A picklist guides warehouse pickers in retrieving items, while a packing list provides details of the items included in a package, used primarily during shipping.
Can picklists be used for inventory management?
Yes, picklists help track inventory levels by showing which items have been retrieved. Coupled with a WMS, they can update stock levels in real-time.
How are picklists prioritized for urgent orders?
Urgent orders are flagged in the system, and their picklists are marked with priority tags, ensuring they are processed and picked before regular orders.
What industries commonly use picklists?
Picklists are widely used in eCommerce, retail, manufacturing, and logistics industries, where inventory storage and order fulfillment are critical operations.
Can small businesses use digital picklists without a WMS?
Yes, small businesses can use basic inventory management tools or software with digital picklist features, making order fulfillment more efficient without heavy investments.
I’m Tammy Waller, a supply chain and logistics specialist with over 10 years of expertise. I’ve been an author and SFL employee for over 10 years.
As an author, I’ve been able to teach others. I love guiding users through supply chain and logistics operations.
I have substantial experience managing logistics operations, supply chain management, transportation, inventory management, and warehousing in shipping-moving and logistic services. I’ve worked on many worldwide logistics and supply chain projects, honing my abilities in negotiating rates, scheduling shipments, and managing vendors.
