Cluster Picking Explained: Should You Use It in Your Warehouse?

If you manage a warehouse, you may struggle with inefficient order picking, high costs, or frequent errors.

These issues can slow down operations and hurt customer satisfaction. You probably searched for cluster picking to find ways to streamline your processes, increase productivity, and improve order accuracy.

In this article, we’re going to explore how cluster picking works and how it can benefit your warehouse.

Table of Contents

• What is Cluster Picking in a Warehouse?
• Why Use Cluster Picking?
• FAQs
• Conclusion

What is Cluster Picking in a Warehouse?

Cluster picking is an efficient order fulfillment strategy used in warehousing operations where items for multiple orders are picked in a single pass through the warehouse. This method optimizes the picking process by reducing the travel time of warehouse workers, enabling them to handle multiple orders simultaneously.

How It Works

Initially, historical order data is analyzed to group similar orders, optimizing pick paths and warehouse layouts to reduce picker travel time.

A Warehouse Management System (WMS) is central to this process, directing pickers in real-time to efficiently collect items from various locations and place them into designated bins on their carts.

After collection, items are verified for accuracy at a consolidation point before being packed and dispatched. The system incorporates continuous feedback mechanisms, allowing for regular performance evaluations and updates, ensuring scalability and improving efficiency over time.

Why Use Cluster Picking?

The primary goal of cluster picking is to increase efficiency, reduce operational costs, and enhance order accuracy. But to discuss it in more depth, please read the points below.

Saves Time

Cluster picking lets pickers handle several orders at once, which means they walk less and do more in less time. This method speeds up the whole process of getting orders ready and out the door, making the warehouse more efficient.

Cuts Costs

By allowing pickers to collect items for multiple orders in one go, cluster picking reduces the amount of time spent on picking. Fewer hours picking means less money spent on labor, helping the warehouse save money. It also frees up pickers to focus on other important tasks, boosting overall productivity.

Increases Accuracy

Using a Warehouse Management System (WMS) with cluster picking helps ensure that the right items are collected for each order. The system guides pickers and checks their work, which helps prevent mistakes. Fewer errors mean happier customers and lower costs from handling returns or corrections.

These reasons show how cluster picking can make warehouse operations not just faster, but also more cost-effective and reliable.

FAQs

What types of warehouses benefit most from cluster picking?

Warehouses with a high volume of small, similar orders, such as e-commerce fulfillment centers, benefit significantly from cluster picking. This method is also advantageous in environments where quick processing and delivery are critical, as it supports faster and more accurate order assembly.

How is batch picking different from cluster picking?

It's easy to confuse batch picking with cluster picking if you're not yet familiar with these methods.

In essence, batch picking involves collecting items for multiple orders simultaneously without immediately sorting them into specific orders. In contrast, cluster picking involves sorting items into specific orders as they are picked.

Each method has its own advantages and disadvantages, and choosing the best one depends on your specific needs.

Can cluster picking be combined with other picking strategies?

Yes, cluster picking can be effectively combined with other picking strategies such as batch picking or zone picking, depending on the warehouse’s needs. For example, items could be batch picked to a central sorting area where they are then cluster picked into specific orders, optimizing both collection and sorting phases.

What training do staff need to effectively implement cluster picking?

Staff training for cluster picking should focus on familiarizing them with the WMS and the specific hardware used in the picking process, such as RFID scanners or pick-to-light systems. Training should also include best practices for efficiently navigating picking routes and accurately sorting items into the correct order bins.

What are some common challenges with cluster picking and how can they be addressed?

Common challenges with cluster picking include managing the complexity of simultaneously handling multiple orders and the potential for increased errors in sorting. These can be addressed through thorough training, continuous process optimization, and leveraging technology to assist pickers in accurately fulfilling orders.

Conclusion

Cluster picking boosts warehouse efficiency by organizing and fulfilling multiple orders simultaneously.

Packiyo enhances this process through features like Mobile Smart Pick, which aids in efficient warehouse navigation, and Automation Co-Pilot, which automates repetitive tasks, reducing errors. Its robust inventory management ensures accurate tracking critical for cluster picking, while integrated shipping and returns streamline post-picking operations.

Read more topics similar to this one on our blog, where we've covered ones like 'AOV Explained', 'What is Pallet Picking', and more.

We hope this has helped you further understand one of the many picking methods available. If you need any more assistance, don't hesitate to contact us.

And as always - take care!