Pick and pack fulfillment involves a complex series of interconnected processes. While an eCommerce shop can get away with packing and shipping their own orders with ease, a medium- to large-sized business can quickly become overwhelmed managing the pick and pack process on their own.
In this blog, we’ll answer the question “what is pick and pack fulfillment?”, cover different picking strategies and their benefits, and explore why partnering with a forward-thinking 3PL can help your business overcome the challenges associated with order fulfillment.
Pick and Pack Fulfillment 101
The pick and pack fulfillment process refers to the steps taken in a warehouse to prepare an online order for shipment and delivery. This order receiving and shipping process has two core components, (1) picking and (2) packing.
Picking
Picking from the warehouse is the process of finding and retrieving the proper quantity of each product from its respective location. Often, each product for an entire order is handpicked by a picker as it is received. Generally, there are four picking strategies, which we’ll explore in further detail below.
Packing
To ensure the finished package arrives undamaged at its final destination in the most cost-effective manner, packing involves placing inventory into the appropriate sized box(es) with the appropriate packaging materials.
To reduce shipping costs and keep orders accurate, your 3PL’s pick and pack strategy should aim to keep orders in fewer boxes and use the right packing material(s) for each order. An efficient warehouse management system can help determine which box is the best choice for the order at hand.
Pick and pack services are the backbone of an experienced warehouse. With quick turnaround times, a high accuracy rate, and the ability to manage quality control, an experienced 3PL can simplify and streamline the entire picking and packing process. Which saves you a lot of time and money in the long run.
Picking and Packing Methods
Different picking methods are better for different companies based on their order volume. While one picking strategy isn’t necessarily better than another, it’s important to partner with a 3PL experienced in all methods of picking and packing so they can find the strategy that’s right for your orders.
Piece Picking
A piece picking order is created by taking the packing slip for a single order. From there, the picker proceeds to pick the items from the shelves for that specific order. Once all the items are available, the picker takes the order to the packing station for packing.
Piece picking is a viable option for small businesses that don’t have to move a lot of inventory on a daily basis. Piece picking isn’t a great option for companies receiving a few dozen or more complex orders in a day, as it can be time-consuming and prone to more inaccuracies than other methods.
Batch Picking
Batch picking is ideal when you have a large number of orders in the warehouse, as it gives pickers the most efficient route through the warehouse. It makes sense to pick the same SKU for several orders at the same time. Those orders will go out faster since a picker won’t have to walk back and forth as often.
Without the proper pick and pack system and up-to-date software, batch picking may prove too difficult for a business to handle on its own. If you’re managing a steady stream of orders on a daily basis, be sure to look for a 3PL with up-to-date fulfillment technology able to handle batch, zone, and/or wave picking.
Zone Picking
Larger fulfillment warehouses will often use a strategy called zone picking. Zone picking allows pickers to stay in a particular zone and pick each order’s products. They then pass them off to another worker, and the process continues until the order goes to the packing station after passing through all the necessary zones.
Zone picking, while effective for large orders, can be incredibly complex if not managed properly and in tandem with up-to-date pick and pack technologies and an optimized warehouse space. A large business should look for a 3PL with advanced warehouse management software experienced in zone picking.
Wave Picking
Wave picking combines zone picking and batch picking. Rather than picking for a single order, workers pick items within zones for a batch of orders and then pass the batch on to the next zone.
The Four Steps of the Pick and Pack Process
Regardless of the picking strategy, there are four steps to the pick and pack process:
- Order receiving. Integration between eCommerce sales channels and warehouse systems is essential. Each time a customer places an order, the fulfillment warehouse software generates a packing slip. A physical copy of the packing slip or a digital copy can be provided, ensuring order accuracy and accountability.
- Order picking. This involves picking the items for the order from warehouse shelves. Choosing the right storage strategy and picking methods is important here, as this is dependent upon the products your business offers and the complexity of your orders. Each business will benefit from different methods depending on its inventory and sales volume.
- Order packing. The order goes to a packing station, where a warehouse packer packs it securely, seals it, and labels it for shipping.
- Order shipping. After an order is packed, a team should sort orders by carrier on the loading dock. That way they’re ready for pickup by carriers when the time comes.
The Benefits of Pick and Pack Fulfillment
As U.S. eCommerce sales continue to grow at around 15% annually, suppliers feel the pressure to satisfy eCommerce customers by delivering a variety of goods with accuracy and at a faster pace. Outsourcing to an experienced pick and pack fulfillment center allows you to:
- Ship items faster
- Free up time that can be spent on other tasks
- Avoid costly mistakes when shipping orders
- Provide a better customer experience
- Handle more orders as your business grows
Warehouse Picking and Packing Best Practices
In order to reduce dimensional weight charges (DIM), products should be packed in the smallest box possible to protect them during shipping. You’ll also need enough infill for the box to protect the products during shipment. To further reduce return rates, shipping charges, and errors during your packing process, below are pick and pack best practices:
- Verify the products on the packing slip match the ones you’re putting into the package on each order.
- Don’t make packers guess the correct box size. Use pick and pack software to calculate the size of the box needed for each order.
- To improve picking and packing, include instructions for each order. Packers can then reach for the correct packing materials quickly when they need them.
Outsourcing Your Pick and Pack Fulfillment
If the growth of your eCommerce business exceeds your fulfillment capacity, it’s probably time to consider a switch to a 3PL. A fulfillment warehouse provides the benefit of hiring a professional team skilled in using the latest picking and packing technology.
The result? Improved order accuracy, reduced shipping costs, and less stress from trying to manage your business and your fulfillment all on your own.
Below are a few of the steps we take at Jay Group to make sure our pick and pack methods are perfect:
- Ensure that warehouse management software is constantly updated. Using the latest software is the best way to offer the best fulfillment solutions.
- Every order and every product is scanned multiple times with barcodes. Implement system checks. This prevents pickers from picking up the wrong product. We also recheck each order during packing to ensure accuracy.
- Calculate the exact dimensions of each box and make sure orders are shipped in the right-sized boxes by feeding this data into a custom box machine.
If your need for pick and pack services outweighs your ability to ship orders, the growth of your business will begin to slow. A 3PL warehouse can free up your space and capital resources, giving your business more room to grow.
At Jay Group, we operate two strategically placed temperature-controlled warehouses across the U.S. The result? Faster delivery times and the utmost accuracy. Contact us today to see how we can help you manage the order fulfillment process.
