Multi-Order-Picking

What is multi-order picking?

Multi-order picking is a picking strategy in which a picker does not process orders one at a time, but instead retrieves items for multiple customer orders simultaneously in a single pass through the warehouse. The picked quantities are kept physically separate — typically via numbered compartments on a picking cart, color-coded totes, or sorting slots on shelving — and are then assigned to their respective orders in a consolidation step. The goal is to significantly reduce travel time per picked item, since a single route through a warehouse zone is used to fulfill multiple orders.

How does multi-order picking work in practice?

The warehouse management system (WMS) forms the core of the process: it groups orders into pick lists that describe spatially optimized routes through the warehouse. In doing so, it determines how many orders can be processed in parallel without exceeding container capacity or becoming unmanageable. In practice, four to twelve orders are typically batched per run, depending on item size, order size, and available cart capacity.

Pickers receive their instructions via mobile radio data terminals, pick-by-voice systems, or pick-by-light displays. Each pick is assigned to the correct order compartment. Errors arise primarily during this assignment step — which is why technical guidance systems such as barcode confirmations or light pointers on cart compartments are particularly important.

The picking run is followed by consolidation: either carried out manually by staff, or handled by an automated sorting system. The higher the order volume and the more granular the assortment, the more worthwhile an automated solution becomes.

What matters when selecting a solution?

The following aspects are critical for warehouse planning and IT:

• WMS functionality: The system must be able to reliably handle order batching, route optimization, and order-accurate assignment. Not every WMS supports multi-order picking natively.
• Number of parallel orders: The optimal batch size depends on item weight, container capacity, and the risk of errors. Too many orders running in parallel increases the likelihood of mistakes and the effort required for consolidation.
• Separation mechanism: Whether cart compartments, bags, or digital assignment — the physical or system-based separation must function reliably within the workflow, even under time pressure.
• Consolidation strategy: Manual consolidation is flexible and cost-effective, but quickly reaches its limits at high volumes. Automated sorting systems require greater capital investment but improve both speed and accuracy.
• Item structure: Multi-order picking is particularly well suited to small, homogeneous assortments. With bulky, heavy, or highly variable items, the effort involved in separation often outweighs the savings in travel time.

Multi-order picking and batch picking are frequently used interchangeably, but differ in focus: batch picking often emphasizes the item-level grouping of similar picks, while multi-order picking emphasizes the parallel processing of complete customer orders. In practice, the boundaries are fluid and vary by vendor.