What are Pick Lists: How and When to Use Them?

A pick list is a list of items, products, or materials that need to be collected or “picked” from a storage location to fulfill orders, restock inventory, or complete production tasks. Picklists are essential for efficient order fulfillment and inventory management processes.

They provide clear instructions to workers on what items to retrieve from storage areas to assemble customer orders or replenish stock. These lists often include information such as item names, quantities, locations, and sometimes additional details like product codes or descriptions.

Let’s uncover how this document works and plays a vital role in shaping the success of online businesses.

A pick list is a document used in order fulfillment that lists all items needed to complete an order. It is also known as a picking list or pick ticket and can be created manually or through Warehouse Management Software (WMS) to streamline the picking process.

Pick lists can range from handwritten paper slips to PDF versions. It contains all the instructions needed for an order to ship the products, like shipment information, item details, and where to find them in the warehouse.

• When a customer places an order, the selected items are compiled into a pick list.
• This pick list is provided to the warehouse worker responsible for collecting and packing the items.
• Warehouse staff use the pick list to gather the correct products efficiently and accurately.

This process ensures accurate and efficient order fulfillment, helping businesses streamline their operations and meet customer expectations.

A well-structured pick list ensures warehouse staff can pick, pack, and ship orders accurately and efficiently. Here’s a breakdown of the essential elements every effective pick list should include:

1. Order Information

This section provides all the key details about the customer’s order, helping warehouse staff match the pick list to the correct package.

• Order Number – A unique identifier for tracking the order.
• Customer Name – Useful for cross-checking during packing and shipping.
• Shipping Address – Ensures the correct delivery destination is verified early.

These elements collectively help ensure accurate and efficient order fulfillment, minimize errors, and enhance customer satisfaction.

2. Item Details

The heart of the pick list—this section outlines exactly what needs to be picked.

• Product Name – The official name or title of the product.
• SKU (Stock Keeping Unit) – A unique code used for quick identification and tracking.
• Variant Info – If applicable, includes size, color, material, etc.
• Quantity – The number of units required for the order.

3. Warehouse Location

This tells the picker exactly where to find each item within the warehouse.

• Zone/Rack/Shelf/Bin Numbers – Organized location data to minimize search time and speed up fulfillment.

4. Item Image

Including an image of each product helps pickers visually confirm they’ve selected the correct item.

• Visual Reference – Reduces errors, especially for products that look similar.
• Ideal for fast-paced environments and training new warehouse staff.

5. Quantity and Weight

Provides logistical details needed during packing and shipping.

• Item Quantity – Confirms how many of each item should be picked.
• Weight – Helps plan shipping and choose appropriate packaging.

In warehouse and order fulfillment operations, the method used to pick products can have a big impact on speed, accuracy, and overall efficiency. Two of the most common methods are batch picking and discrete picking.

Let’s take a closer look at how each works, their pros and cons, and when to use them.

Batch Pick List

A batch pick list is a type of pick list where multiple orders with similar or overlapping items are grouped together for picking. Instead of picking items for each order individually, the picker gathers all the required items for multiple orders at once.

Benefits:

• Reduces walking time by avoiding multiple trips for similar items.
  
• Ideal for high-volume operations with overlapping products.
  
• Improves overall picking speed and warehouse productivity.

Discrete Pick List

A discrete pick list is a more traditional approach where each order has its own separate pick list.

Pickers follow individual pick lists, gathering items for one order at a time. This method ensures that each order is processed independently, which can be particularly useful for maintaining order accuracy and meeting specific customer requirements.

Benefits:

• High order accuracy, as there’s no mixing of items between orders.
  
• Easier to track and manage individual orders.
  
• Ideal for customized, fragile, or high-value items where precision is essential.

Batch vs. Discrete: Which One Should You Use?

Choosing between batch and discrete pick lists depends on several factors:

Factor	Batch Picking	Discrete Picking
Order Volume	High	Low to Moderate
Item Overlap	Frequent	Rare or Unique
Warehouse Layout	Large & Spread Out	Compact
Need for Speed	High Priority	Moderate
Focus on Accuracy	Moderate	High Priority
Order Customization	Minimal	Frequent

The choice between batch and discrete pick lists depends on factors such as order volume, warehouse layout, item characteristics, and operational efficiency goals.

Batch picking is often favored in scenarios with a high volume of orders containing similar items, while discrete picking may be preferred when order customization and accuracy are paramount.

A pick list is necessary for several reasons in the context of eCommerce and inventory management:

Efficient Order Fulfillment: A pick list outlines which items and quantities need to be gathered from the warehouse to fulfill customer orders. This precision ensures the right products are selected, reducing errors and expediting the fulfillment process.

Streamlined Operations: Pick lists provide a structured and organized approach to order picking. Warehouse personnel can follow the list to navigate the warehouse efficiently, reducing the time and effort required to locate and gather items.

Reduced Fulfillment Errors: With clear instructions and item details, pick lists minimize the chances of mistakes in picking the wrong items or quantities. This improves customer satisfaction by ensuring that customers receive the correct products.

Batch Picking Efficiency: In scenarios with multiple orders, batch pick lists enable the picking of items from multiple orders together. This method saves time and reduces unnecessary movement within the warehouse.

In summary, a pick list is necessary to enhance order accuracy, streamline operations, manage inventory effectively, and improve efficiency in eCommerce and warehousing environments.

The three common methods for grouping pick lists in warehouse operations are:

Zone Picking

In zone picking, the warehouse is divided into different zones or areas, each assigned to specific pickers. Each picker is responsible for picking items only within their designated zone.

Once all zones are picked, the items are consolidated for packaging and shipping. Zone picking is efficient for larger warehouses and high order volumes, as it reduces picker travel time and increases overall efficiency.

Batch Picking

Batch picking involves picking multiple orders’ items together, often based on similarities in items or their locations. Pickers gather items for multiple orders in a single trip through the warehouse.

After picking, the batch is sorted and divided into individual orders for packaging and shipping. Batch picking is useful when there are many small orders or orders with similar items, as it minimizes travel time within the warehouse.

Pick-to-Order

Pick-to-Order assigns pickers to fulfill individual customer orders. Each picker is given a pick list for a single order, and they gather all the required items for that order. This method ensures order accuracy and is suitable for customized or unique orders, as well as when order sizes vary widely.

Here are some best practices for creating and using picklists in inventory management and order fulfillment:

1. Use a Clear and Organized Format

A well-designed pick list should be easy to read and follow.

• Use legible fonts and consistent formatting for headings and product details.
  
• Organize information logically – group items by zone, category, or order priority.
  
• Include section headers or dividers to improve readability, especially in large warehouses.

2. Include Accurate Item Descriptions

Accuracy in product details is essential to avoid confusion during picking.

• Ensure each item includes the correct name, SKU, and any relevant attributes (e.g., size, color, model).
  
• Include brief descriptions for clarification, which are especially helpful for new or similar-looking products.
  
• Consistency between pick lists, product listings, and inventory systems reduces errors.
  

3. Add Barcodes and Item Images

Visual and scannable elements can significantly enhance speed and accuracy.

• Barcodes allow for quick scanning, reducing manual entry and human error.
  
• Product images help pickers visually confirm they’re grabbing the correct item.
  
• Especially helpful for training new staff and handling large inventories.

4. Prioritize and Sequence Items Strategically

Help pickers move through the warehouse more efficiently.

• Sequence items in picking order based on warehouse layout to minimize backtracking.
  
• Group items that are stored close together to reduce travel time.
  
• For urgent orders, consider highlighting or prioritizing certain items on the list.

5. Use Digital Pick Lists When Possible

Go paperless with real-time updates and improved flexibility.

• Implement Warehouse Management Systems (WMS) or dedicated mobile picking apps.
  
• Digital pick lists allow for live inventory updates, status tracking, and error reduction.
  
• Cut down on paper waste and streamline communication between teams.

6. Keep Pick Lists Updated with Real-Time Data

A pick list is only useful if it reflects what’s actually available.

• Sync your pick lists with real-time inventory systems to avoid picking out-of-stock items.
  
• Clearly mark unavailable or backordered items to prevent delays or mistakes.

7. Incorporate Quality Control Checks

Don’t let one small mistake lead to a return or negative review.

• Perform quality checks at multiple points—after picking, during packing, and before shipping.
  
• Cross-reference the pick list with the final items to verify order accuracy.
  
• Use a checklist or digital confirmation system to mark completed picks.

8. Have Backup Copies Available

Even with digital systems, it’s smart to plan for disruptions.

• Keep printable backups in case of technical failures, system outages, or mobile device issues.
  
• Ensure backups are stored securely and updated regularly to reflect current inventory data.

By following these best practices, businesses can optimize their pick list processes, reduce errors, enhance efficiency, and deliver a better overall customer experience.

In eCommerce and inventory management, the pick list emerges as a silent hero, steering the course of seamless order fulfillment. With its ability to guide warehouse personnel through the labyrinth of products, ensure accuracy, and expedite the journey from shelf to shipping, the pick list proves to be an indispensable tool.

By adhering to best practices and embracing the potential of pick lists, businesses can not only save time and reduce errors but also elevate customer satisfaction to new heights. The pick list is undeniably the cornerstone upon which a part of the success of eCommerce fulfillment rests.