Kommissioniersystem

What is a picking system?

A picking system describes the totality of all technical, organizational, and information technology components that work together to retrieve goods selectively from warehouse stock and consolidate them into orders. It is not about a single machine or piece of software, but rather an integrated system comprising warehouse layout, picking method, conveyor technology, warehouse management software, assistance systems, and replenishment logic. The distinction from a mere picking method is important: the method describes how an order is processed (e.g., single order or batch); the system describes the entire implementation, including all technical and process-related framework conditions.

How does a picking system work in practice?

In practice, a fundamental distinction is made between two organizational principles: person-to-goods and goods-to-person. With the person-to-goods principle, the picker moves through the warehouse and retrieves items at their storage location. With the goods-to-person principle, the technology — such as an automated small-parts warehouse (AS/RS), a shuttle system, or an AutoStore — transports the load unit to the workstation. Which principle makes sense depends on factors such as order volume, product variety, unit size, and available floor space.

The IT side controls the entire system: a Warehouse Management System (WMS) handles order management, assigns pick tasks, manages storage locations, and coordinates replenishment. Assistance systems such as Pick-by-Light, Pick-by-Voice, or augmented reality guide employees and reduce error rates. Conveyor technology connects the individual stations and ensures that goods and load carriers arrive at the right place without manual transport routes.

Capacity planning is critical for peaks and load spikes. A picking system must be designed to operate stably even under peak load. This includes not only throughput design but also a well-thought-out redundancy and contingency concept.

What matters when making a selection?

Selecting a suitable picking system depends on several dimensions:

• Throughput and peak capability: How many picks per hour must be achievable at peak, and how much does utilization fluctuate?
• Product range and warehouse structure: Large, heavy, or bulky items require different solutions than small parts in tray format.
• Degree of automation: Fully automated systems offer high throughput and low error rates, but are capital-intensive and vendor-specific. Dependence on a single system supplier is a risk factor that should be assessed in the business case.
• Integration with existing IT: The picking system must communicate reliably with ERP, WMS, and any other systems. Integration depth and available interfaces vary by vendor and should be evaluated early.
• Operation, maintenance, and spare parts supply: Especially with automated systems, long-term operating costs and dependencies arise that significantly influence the total cost of ownership.

There is no universally superior solution. Which picking system is the right fit must be assessed individually based on the specific requirements.