Pick and Pack Order Fulfillment

Here’s an expert guide to improve and optimise your pick and pack service for maximum efficiency.

Picking and packing are important parts of the order fulfillment process. They ensure that customers receive their products on time and in perfect condition. As global online sales and customer expectations continue to rise, it’s important to enhance these processes for more smooth and efficient warehouse operations.

Moreover, many businesses are facing the challenge of limited storage space. This results in skyrocketing warehouse rents. It’s no secret that order picking is often the most time-consuming and costly activity in a typical warehouse. This factor influences the customer satisfaction and ultimately the entire supply chain. Therefore, it’s becoming more important to maximise your storage facility, optimising space utilisation and speeding up shipment turnaround.

So, Flexi Couriers is here with some effective tips & strategies to pick and pack customer orders quickly and accurately. Keep reading to update and improve your warehouse operations.

To begin, first let’s clarify what actually is picking and packing in order fulfillment.

What is Pick and Pack?

“Pick and Pack is a key process in warehousing that involves selecting items from inventory to fulfill customer orders. This means finding, retrieving, and gathering the products needed before they are packed for shipping.”

Once the items are picked, they go through the packing stage. Here, the products are carefully organised, placed in boxes or bags, and labeled for delivery. This step is important because it ensures that the items are safe during transfer and arrive at the customer’s location in great condition.

Here are four main steps involve in pick and pack process:

No.

Step

What it Involves

1.

Receiving Orders

Orders are received from the website and logged into the warehouse management system (WMS).

2.

Picking Orders

Warehouse staff collect items based on the picking slip.

3.

Packing Orders

Items are verified, packed securely, and labeled for shipping.

4.

Shipping Orders

Packed orders are moved to the loading area for carrier pickup.

Explore more about: The Ultimate Guide to Pick and Pack Services

As we are done with the basics. Next, we will explore some effective strategies and expert tips for efficient pick and pack solutions.

13 Tips to Improve Pick and Pack Process for Quick & Efficient Order Fulfillment

1. Simplify Order Picking: Break It Down into Manageable Steps

Instead of giving pickers a long list of items, present one item at a time. This approach reduces the distance they have to walk and simplifies the packing. Focus on the six key areas to boost order fulfillment:

  • Organize Stock: Keep everything tidy and easy to find.
  • Use Picking Bins: Designate specific containers for items.
  • Train and Motivate Staff: Provide proper training and incentives.
  • Ensure Safety in Picking Zones: Keep work areas hazard-free.
  • Optimize Floor Space: Use your space wisely.
  • Choose Efficient Packaging: Select materials that protect items and reduce waste.
  • Prepare for the Unexpected: Be ready for surprises that could disrupt your workflow.

These basics create a solid foundation for improving your sales and revenue.

2. Keep the Packing Stations Organised and Well Stocked

Make sure packing stations have all the supplies needed for packing. Get feedback from your team about which materials are easy to use and which ones slow them down. Arrange the stations so everything is within easy reach to minimize walking and stretching.

Consider using slotting, which involves organizing storage areas with dividers. This method can help reduce accidents, prevent product damage, and speed up retrieval times. Make sure your software tracks inventory locations accurately during this process.

3. Apply 80/20 Rule with ABC Analysis

The 80/20 rule suggests that around 80% of your sales can come from just 20% of your products.

To leverage this, you can use ABC analysis, which helps you organise your inventory into three categories based on their importance and sales volume:

  • Category A: This group includes about 10-20% of your total inventory but contributes approximately 70-80% to your revenue. These are your best-selling items, so it’s wise to store them close to the packing station. This placement saves time during the picking process, speeding up overall order fulfillment.
  • Category B: This category represents about 30% of your inventory and accounts for 15-20% of your sales. You can position these items slightly further from the packing area since they are not sold as frequently.
  • Category C: This group consists of around 50% of your inventory but contributes only about 5% to your total sales. Sometimes, these items can cost more to store than they’re worth. It’s best to place them at the farthest point in your warehouse to optimize space and efficiency. 

4. Invest in Pick and Pack Software

Using advanced warehouse picking software can greatly improve your picking and packing efficiency.

This software can streamline your entire pick-pack-ship process and reduce errors. You can customize the system for different picking methods, such as batch or zone picking, to speed up delivery and ensure accuracy.  

5. Use Images for Easy Identification

Since our brains process images much faster than words, use photographs, diagrams, and visual cues wherever possible.

Display images of items alongside their storage locations. Instead of letters and numbers, use colors and shapes for labeling shelves. This makes it easier for pickers to locate items quickly.

6. Consider Cross-docking for Efficiency

Cross-docking involves unloading incoming inventory and immediately reloading it onto outgoing shipments. This method is particularly useful for businesses that sell products in bulk, as it speeds up the turnaround time and reduces storage costs.

For larger retailers, cross-docking can also help distribute incoming inventory across multiple fulfillment centers.

7. Use Mobile Technology

Manual picking can slow down the process, as it often requires logging entries in physical registers.

Instead, use mobile barcode and RFID scanners that connect wirelessly to your warehouse management system (WMS). When an item is scanned, the stock count updates automatically. This technology also alerts you if a wrong barcode is scanned, reducing manual verification time. 

8. Optimise Your Warehouse Layout

The layout of your warehouse has a big impact on efficiency. Analyse your sales patterns and adjust the layout accordingly.

For small to medium-sized operations, consider a volume-based storage setup. High-volume eCommerce retailers might benefit from chaotic or automated warehousing structures to keep up with demand. 

9. Manage Slow-Moving Items Effectively

Limited warehouse space can hinder picking efficiency. Items picked from ground level are quicker to retrieve than those stored higher up.

So, consider placing slow-moving items on higher shelves and keeping frequently picked items at ground level. This strategy helps your team save time during order fulfillment.

10. Leverage Business Intelligence and Big Data

Your warehouse generates a significant amount of operational data. By analysing this data, you can gain valuable insights into the processes that enhance your picking and packing efficiency.

Additionally, it can help identify any holdups that slow down your order fulfillment.

Many advanced Warehouse Management Systems (WMS) come equipped with dashboards that allow you to create detailed reports. By utilising this data, you can continuously improve your pick and pack methods and processes.

11. Optimise Your Returns Process for Better Customer Experience

While reverse logistics may not be part of the picking and packing workflow. It is important not to overlook it.

According to a survey, 92% of customers are more likely to shop with a retailer again if they can easily return products.

When customers return items, they often expect quick service. Therefore, it’s important to have a solid system for handling returns smoothly and efficiently. This is where third-party logistics (3PL) can be beneficial. They manage the entire fulfillment process, including complex return logistics, freeing you up to focus on your core operations.

12. Personalise the Packing Slip

Including the packer’s first name and photo on each packing slip can create a sense of accountability. This simple addition not only improves the customer experience but also fosters a greater sense of responsibility among your packing team.

13. Train and Motivate Your Warehouse Staff

Regardless of whether you employ human workers or use picking robots, there will always be a need for packers and shippers. Mistakes can happen, so it’s important to train your staff on best practices for the pick-pack-ship process to improve efficiency and accuracy.

In addition to training, consider implementing a rewards system to keep your employees motivated. Recognising achievements can lead to higher performance levels. You can offer rewards for:

  • Reducing turnaround time
  • Achieving targeted accuracy
  • Increasing the volume of shipments

Are you looking for fast and reliable pick and pack solutions?

Partner with Flexi Couriers for Efficient Pick and Pack Services for Your Business

Being the best pick and pack company, we provide affordable and efficient solutions according to meet your business needs. From frozen storage to fast dispatch, we handle it all with care and precision.

Our tailored pick and pack solutions are designed to optimise every step of your order fulfillment process. With features like real-time tracking and temperature-controlled logistics, Flexi Couriers is the trusted choice for businesses across Perth.

Contact us today to get flexible and scalable delivery services.

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