Zone Picking

Zone picking is an order fulfillment strategy where the warehouse is divided into zones, and each picker works only in their assigned zone. Orders that require items from multiple zones are either passed between zones (sequential) or combined later (parallel).

How Zone Picking Works

Basic Concept

Warehouse divided into zones:
┌─────────┬─────────┬─────────┐
│ Zone A  │ Zone B  │ Zone C  │
│ Picker 1│ Picker 2│ Picker 3│
│         │         │         │
│ SKUs    │ SKUs    │ SKUs    │
│ 1-500   │ 501-1000│ 1001+   │
└─────────┴─────────┴─────────┘

Each picker stays in their zone only.

Order Flow Example

Order has items from Zones A, B, and C:

Sequential (Pick and Pass):
Zone A → picks items → passes to Zone B
Zone B → adds items → passes to Zone C
Zone C → adds items → complete order

Parallel:
Zone A, B, C pick simultaneously
→ All meet at consolidation
→ Items combined into one order

Types of Zone Picking

Sequential (Pick and Pass)

• Tote moves zone to zone
• Each zone adds items
• Linear flow
• Good for conveyor systems

Parallel

• All zones pick simultaneously
• Combine at consolidation station
• Faster for multi-zone orders
• Requires sorting/combining

Combined

• Mix of sequential and parallel
• Based on order characteristics
• Flexible approach
• Optimized for throughput

Zone Design Considerations

Factors for Zone Layout

Zone Size Guidelines

Goal: Balance picker workload

Zone too small:
- Picker idle time
- Too many zones to manage

Zone too large:
- Picker walks too much
- Loses zone expertise

Target: Similar pick volume per zone

Zone Picking Benefits

Efficiency Gains

• Reduced travel time
• Picker familiarity with zone
• Less congestion
• Parallel processing

Operational Advantages

• Easier training
• Clear accountability
• Specialized equipment per zone
• Scalable with volume

Quality Improvements

• Expertise in zone items
• Better error detection
• Consistent process
• Easier supervision

Zone Picking Challenges

Multi-Zone Orders

Challenge: Order needs items from 3 zones

Solution options:
1. Sequential pass-through
2. Parallel + consolidation
3. Batch items, then sort

Workload Balancing

Solution: Reallocate SKUs or staff

Zone Bottlenecks

• One zone slows entire process
• Buffer zones help
• Flexible staffing
• Monitor in real-time

Zone Picking Equipment

Zone-Specific Tools

Supporting Systems

• Conveyor between zones
• Totes for transport
• Scanners for verification
• WMS for direction

Implementing Zone Picking

Steps

1. Analyze product velocity
2. Design zone layout
3. Assign SKUs to zones
4. Determine staffing
5. Set up equipment
6. Configure WMS
7. Train pickers
8. Monitor and adjust

Zone Assignment Logic

WMS determines pick route:

Order 12345:
- Item A: Zone 1
- Item B: Zone 2
- Item C: Zone 1
- Item D: Zone 3

Pick instructions:
Zone 1: Items A, C
Zone 2: Item B
Zone 3: Item D

Consolidation: Station 5

Zone Picking Metrics

Key Performance Indicators

Monitoring

• Real-time dashboards
• Zone comparison
• Bottleneck alerts
• Labor allocation

Zone Picking Best Practices

Design

1. Group fast movers
2. Balance workload
3. Minimize zones touched
4. Consider order profiles
5. Plan for growth

Operation

1. Cross-train pickers
2. Flexible zone boundaries
3. Monitor and adjust
4. Clear zone ownership
5. Regular optimization

Zone Picking + Other Methods

Zone + Wave

Wave 1 released:
- Zone A picks Wave 1 items
- Zone B picks Wave 1 items
- Zone C picks Wave 1 items

All zones work on same wave

Zone + Batch

Zone A batches similar items:
Pick all Widget-A for 10 orders
Then pick all Widget-B for 8 orders

More efficient than order-by-order