Cluster Picking: The Merchant’s Guide to Faster, More Efficient Order Fulfillment

To fully leverage the benefits of cluster picking, it’s essential to optimize your warehouse layout for maximum efficiency. This involves strategically arranging your inventory to minimize travel time and ensure a smooth flow of goods through the ecommerce fulfillment process. 

Consider the following tips when optimizing your warehouse for cluster picking: 

• Group similar products together: Organize your inventory so that items frequently ordered together are located in close proximity. This reduces the distance pickers must travel to collect all the necessary items for a given set of orders. 
• Utilize vertical space: Make the most of your warehouse’s vertical space by implementing tall shelving units and utilizing appropriate equipment (e.g., ladders, cherry pickers) to access high-level items safely. This allows you to maximize storage capacity while maintaining efficient picking routes. 
• Implement clear labeling and signage: Ensure that all shelves, bins, and aisles are clearly labeled to help pickers quickly locate the items they need. Use a consistent and intuitive labeling system that aligns with your WMS for seamless integration. 
• Analyze order data to inform layout decisions: Regularly review your order history and product velocity data to identify trends and patterns. Use this information to make data-driven decisions about inventory placement and picking route optimization. 

By carefully designing your warehouse layout to support cluster picking, you can further enhance the efficiency and productivity gains associated with this powerful fulfillment method. A well-organized warehouse not only streamlines the picking process but also contributes to improved accuracy, reduced errors, and a more seamless overall fulfillment operation. 

In single-order picking, warehouse workers focus on completing one order at a time.  

This method involves picking all the items for a single customer order before moving on to the next one. While this approach is straightforward and easy to implement, it can be time-consuming and inefficient, especially for businesses with high order volumes. 

Compared to cluster picking, single-order picking typically results in longer travel times and lower overall productivity. However, it may still be appropriate for businesses with low order volumes or those just starting out with a very limited number of SKUs. 

Batch picking refers to picking several identical orders simultaneously. The key difference between batch picking and cluster picking lies in the type of order being picked: batch picking deals with identical orders (i.e., orders that have the exact same SKUs in the exact same quantities), while cluster picking is for similar orders (i.e., orders that may contain some of the same SKUs, but not necessarily all of the same items or in the same quantities).  

Batch picking can be more efficient when dealing with subscription orders, gift sets, bundles, and other orders that contain the same SKUs every time. However, cluster picking generally offers greater flexibility and efficiency for businesses with more diverse product ranges and order profiles. 

In zone picking, the warehouse is divided into distinct zones, with each zone containing a specific set of products. Pickers are assigned to particular zones and are responsible for picking items only within their designated areas. This approach can be combined with cluster picking to further enhance efficiency. 

For example, a warehouse might be divided into zones based on product categories, with pickers in each zone using cluster picking to gather items in that zone for multiple different orders at once. This hybrid approach leverages the benefits of both methods, allowing for efficient picking within each zone while still consolidating orders across the entire warehouse. 

Wave picking involves scheduling picking tasks based on predefined order groupings, known as waves. Each wave represents a specific set of orders – often similar to each other – that are picked, packed, and shipped together. This approach focuses on optimizing the timing and sequencing of picking tasks to maximize efficiency and meet specific shipping deadlines. 

While wave picking emphasizes scheduling and order grouping, cluster picking is less regimentally structured, and often puts orders on carts simply because they’re next up in the queue.  

However, these two methods can be used together to create a highly efficient fulfillment operation. For example, businesses can use wave picking to group orders based on shipping deadlines, then apply cluster picking within each wave to minimize travel time and maximize picker productivity. 

One of the most significant benefits of cluster picking is the reduction in travel time and distance for warehouse workers. When pickers collect items for multiple orders simultaneously, they make far fewer trips through the warehouse and significantly reduce the time spent walking between locations. 

This translates into: 

• A substantial increase in overall productivity. 
• A higher number of orders processed per hour.  
• Faster fulfillment times. 
• Higher customer satisfaction. 

Another key benefit of cluster picking is the significant increase in order throughput. Processing multiple orders concurrently means businesses can dramatically improve the efficiency of their fulfillment operations and handle a higher volume of orders without overburdening their workforce. 

This increased throughput is particularly valuable for ecommerce businesses that are: 

• In the middle of a peak season. 
• Striving to meet demanding shipping deadlines, such as 2-day or same-day delivery promises.  
• Experiencing sudden spikes in order volume, such as promotional events or unexpected viral moments.  

With cluster picking, businesses can handle these increased demands without compromising on speed or accuracy, and maintain a high level of customer satisfaction even during the busiest periods. 

In addition to improving fulfillment speed and efficiency, cluster picking can also help ecommerce businesses reduce their labor costs, since it reduces the number of labor hours required per order. 

For instance, a business that implements cluster picking may be able to process the same number of orders with 20-30% fewer labor hours compared to single-order picking. This reduction in labor costs boosts your bottom line, especially for businesses dealing with high tight profit margins, labor shortages, and rising wage costs. 

While some may assume that consolidating multiple orders into a single picking run could lead to increased errors, cluster picking can actually improve accuracy when implemented with the right verification systems and technology. 

This is because cluster picking relies on consistent barcode scanning and other verification processes into the cluster picking workflow, which ensures that the correct items are selected and sorted into the appropriate totes or containers for each order. This systematic approach helps prevent mistakes such as missing items or incorrect product selections, which can lead to costly returns and dissatisfied customers. 

Finally, cluster picking offers ecommerce businesses a highly scalable solution for managing growth and adapting to changing demand. As order volumes increase, businesses can easily adjust their cluster picking processes to accommodate the additional workload without requiring a proportional increase in staff or resources. 

This scalability is particularly valuable for businesses experiencing rapid growth or seasonal fluctuations in demand. By implementing cluster picking, these businesses can handle rising order volumes efficiently, maintaining fast and accurate fulfillment even as their operations expand. 

Moreover, cluster picking can be adapted to support both B2C and B2B fulfillment needs, making it a versatile solution for businesses with diverse customer bases. Whether processing small, individual orders or larger, bulk shipments, cluster picking can be customized to meet the specific requirements of each fulfillment scenario. 

While cluster picking offers significant benefits on its own, it’s most effective when it’s paired with the right technology. If you’re considering adopting cluster picking, consider implementing the following tools and systems. 

Leveraging WMS for optimized pick paths 

A critical component of a successful cluster picking implementation is a robust warehouse management system (WMS) that can optimize pick paths and guide pickers through the most efficient routes.  

The right WMS will meet all your brand’s requirements, and be able to: 

1. Use sophisticated algorithms to analyze order data, inventory locations, and warehouse layout to determine the shortest possible path for each picking run. 
2. Dynamically generate optimized pick paths, minimizing the travel time and distance required to collect all the items for a given cluster of orders. 
3. Adapt to real-time changes in inventory locations or order priorities, ensuring that pickers always follow the most efficient path based on the current state of the warehouse. 

Mobile scanning and verification technology 

Equipping pickers with handheld scanners or mobile devices ensures that the correct items are selected and sorted into the appropriate totes or containers for each order. 

These mobile scanning devices guide pickers through the picking process, providing real-time information on item locations, quantities, and order details. As pickers scan each item, the system verifies that the correct product has been selected and updates the order status accordingly.  

This real-time verification helps prevent errors and ensures that orders are picked accurately, even when multiple orders are being processed simultaneously. It also eliminates the need for manual data entry or paper-based picking lists.  

Voice-directed picking integration 

Voice-directed picking is another innovative technology that can be integrated with cluster picking to further enhance efficiency and productivity. With voice-directed picking, pickers wear headsets connected to the WMS, which provides audible instructions and prompts to guide them through the picking process. 

By freeing pickers’ hands and eyes from manual data entry or paper-based picking lists, voice-directed picking: 

• Allows workers to focus solely on the task of locating and selecting items.  
• Speeds up the picking process (since workers won’t have to stop and consult written instructions). 

To successfully implement voice-directed picking with cluster picking, businesses must ensure that their WMS is compatible with voice technology and that their warehouse infrastructure can support the necessary hardware and connectivity. Additionally, pickers will require training on how to use the voice system effectively and adapt to the hands-free picking process. 

One of the key advantages of cluster picking is its adaptability to various business scenarios and requirements. Here are some ways you can customize your cluster picking approach based on your business’s unique circumstances.  

Cluster picking for fast-growing ecommerce brands 

For ecommerce brands experiencing rapid growth, cluster picking offers a scalable solution that can keep pace with increasing order volumes and customer demands.  

As businesses expand their product lines and customer base, they can easily adapt their cluster picking processes to handle the additional workload without sacrificing speed or accuracy. 

To ensure that cluster picking remains efficient as order volumes grow, businesses should focus on: 

• Continuously optimizing their processes and technology. 
• Regularly reviewing and adjusting pick paths, cluster sizes, and inventory layouts to maintain optimal performance. 
• Investing in advanced WMS solutions and mobile scanning technology to automate and streamline the picking process, enabling businesses to handle higher order volumes with minimal manual intervention. 

Adapting cluster picking for varied product types 

Depending on the nature of the products being picked, businesses may need to modify their cluster picking strategies to ensure that items are handled safely, efficiently, and accurately. 

For example, when picking fragile items such as glassware or electronics, businesses may need to use specialized packaging materials and handling procedures to prevent damage during the picking and packing process. This may involve using separate totes or containers for fragile items, or implementing additional verification steps to ensure that these products are picked and packed correctly. 

Similarly, when dealing with apparel or other soft goods, businesses may need to adapt their cluster picking processes to accommodate different sizes, colors, and styles. This may require using specialized equipment such as garment racks or hanging systems to keep items organized and easily accessible during the picking process. 

To optimize cluster picking for different product categories, businesses should analyze their inventory data and order patterns to identify common product groupings and characteristics. This information can then be used to design customized picking strategies and workflows that maximize efficiency and accuracy for each product type. 

Seasonal scaling with cluster picking 

For many ecommerce businesses, managing seasonal peaks in demand is a critical challenge that can strain their fulfillment operations and resources. Cluster picking can be a valuable tool for scaling fulfillment operations during these peak periods, enabling businesses to handle higher order volumes without compromising on speed or accuracy. 

To prepare for seasonal peaks, businesses should focus on: 

• Ramping up their cluster picking operations well in advance of the anticipated surge in demand (e.g., hiring and training additional temporary staff, expanding warehouse space or equipment, and optimizing inventory levels to ensure that popular products are readily available for picking). 
• Training temporary staff on cluster picking procedures, prioritizing clear, concise instructions and hands-on practice to ensure that new hires can quickly become proficient in the picking process. 
• Adjusting their cluster picking strategies to accommodate the additional workload. This may involve increasing the size of picking clusters, reassigning staff to high-demand areas of the warehouse, or implementing additional quality control measures to maintain accuracy under pressure. 

By proactively planning for seasonal peaks and leveraging the flexibility and scalability of cluster picking, ecommerce businesses can successfully navigate even the busiest periods without compromising on customer satisfaction or operational efficiency.