What is the Pick, Pack and Ship Process?

The pick-pack-ship process is an essential part of order fulfillment. It involves the selection, packing, and shipping of products to customers. This process is used by both retailers and wholesalers to fulfill customer orders.

When a customer places an order, an OMS (order management software) routes it for fulfillment. The pick process involves selecting items from the warehouse (or brick-and-mortar store) for shipment. This is typically done manually by staff, but automated systems can be used as well.

Once the items are selected, they are packed into boxes or other containers for shipping. Packing will usually involve adding materials like foam peanuts or air pillows to protect the order during shipment, as well as affixing any necessary labels or including special information. This step is essential to ensure that the items are protected during shipping and that the right items are being shipped to the right customers.

The last step in the process is shipping. Once the items have been packed, they are sent to the customer. This can be done through a variety of methods (ground, air, international, etc.). Pick, pack, and ship is a fundamental part of order fulfillment, and, when executed properly, ensures that customers receive the right items, undamaged, and in a timely manner. 

Optimize Your Order Fulfillment: The Benefits of Pick and Pack

Pick and Pack Methods Reduce Order Processing and Packaging Time

A variety of different methods are involved in the pick and pack process, and all provide benefits to an eCommerce merchant.

Directed picking involves warehouse staff receiving pick lists and following the most efficient route to pick items. This type of order picking is used to increase the efficiency of the picking process and is often combined with other automated technologies, such as voice-directed picking and radio frequency identification (RFID) readers. Directed picking is used in many warehouses and distribution centers to reduce errors and increase efficiency.

Batch picking involves grouping a batch of orders together, usually by product type, and picking all the items off the warehouse shelves for each order at once. This reduces the amount of time spent on each order since all the items can be picked at once. It also improves accuracy since similar items are grouped together and can be checked in one go.

Zone picking is a method of order fulfillment where each order picker is assigned to pick items within a specific area of the warehouse. This increases efficiency as each picker only needs to travel to their assigned zone to pick items. It also reduces the chance of errors since order pickers don't need to travel around the entire warehouse.

Wave picking involves breaking up the order picking process into “waves,” which are then picked and packed in a predetermined order. Wave picking is an efficient way of picking orders as it reduces the need for backtracking and allows for the picking process to be completed faster. It is also beneficial for larger warehouses, as it helps to reduce the number of workers needed for the order picking process. Regardless of the picking method used, all will map the most efficient route to streamline the process.

Automated packing lists are a method of order fulfillment that uses software to generate packing slips for each order. This reduces the amount of time spent on each order since packers know exactly the proper packing materials to use at the packing station and also eliminates the waste caused by overuse of those same materials.

Increased Accuracy Improves Inventory Management

Increased accuracy from optimized pick and pack processes can significantly improve inventory management and provide numerous benefits to a business. Fewer errors ensure that inventory levels are more accurate, allowing businesses to better predict future demand and adjust stocking levels accordingly. This can reduce costs associated with overstocking or understocking, as well as the need for additional staff resources to manage inventory. Furthermore, optimized pick and pack processes can also reduce lead times and delivery times, making inventory management more efficient and leading to increased customer satisfaction.

Pick and Pack Software Lowers Costs Associated with Manual Order Fulfillment Processes

By automating the process of picking, packing, and shipping orders, businesses can reduce labor costs and increase efficiency. This type of automation helps to streamline the order fulfillment process, reducing the amount of time it takes to fulfill an order, thereby reducing labor costs.

Additionally, because pick and pack methods reduce the amount of manual labor required, they can help to reduce the costs associated with errors and mistakes that can occur during manual order fulfillment processes.

Furthermore, automation software can help to reduce the amount of time and money spent on packaging and shipping, as automated systems can quickly and accurately package and label orders for shipment. Finally, pick and pack methods can help to reduce the amount of time it takes to fulfill orders, allowing businesses to better manage their inventory and reduce overhead costs.

Streamline Warehouse Operations with an Optimized Pick, Pack and Ship Process

With an optimized pick, pack and ship process, warehouse management operations can be more efficient and cost-effective. To begin, warehouses should employ barcode technology to track products and orders. This eliminates the need for manual entry and ensures accuracy in product tracking.

Additionally, warehouses should consider a split-case picking system, which allows for the fulfillment of individual orders from a single carton or pallet. This reduces the time spent fulfilling orders and increases the speed of order processing. 

Lastly, warehouses should establish a paperless system of tracking orders and creating shipping labels to further reduce manual labor and increase efficiency. When implemented properly, these strategies can greatly improve the efficiency of warehouse operations and reduce costs.

Challenges to Optimizing the Pick, Pack and Ship Process in Your Warehouse

While the process sounds very straightforward, several issues can disrupt an efficient pick, pack and ship process.

Inaccurate Inventory Tracking Disrupts Fulfillment Processes

Poor tracking of incoming goods, inadequate storage conditions, incorrect count of existing stock, and manual management of multiple SKUs are all potential factors that can lead to inaccurate inventory tracking, and the impact on the pick, pack, and ship process can be significant.

When inventory tracking is not accurate, it can lead to delays in order fulfillment as workers scramble to identify and locate the correct items. In addition, inaccurate inventory tracking can lead to incorrect orders being shipped to customers, resulting in customer dissatisfaction and additional costs associated with returns and refunds. Furthermore, inaccurate inventory tracking can lead to out-of-stock situations, resulting in lost sales opportunities. To ensure the pick, pack, and ship process runs smoothly, accurate inventory tracking is essential.

Manual Processes Create Multiple Problems

Without automation, the pick, pack, and ship process can be significantly hindered. Manual processes can lead to errors, slowdowns, and bottlenecks that can ultimately decrease customer satisfaction. Automation increases accuracy, efficiency, and speed in order fulfillment, allowing businesses to meet customer demands and expectations. Automation also eliminates the need for manual processes, freeing up personnel to focus on more important tasks. Finally, automation reduces the chances of costly mistakes being made and can help to reduce overhead costs.

Lack of Software Integration Can Spell Disaster

Proper, seamless software integration is critical for accurate order fulfillment. Without integration between inventory management software and warehouse management software, it can be difficult to ensure that the right items are being picked, packed and shipped. This can lead to inefficient processes, customer dissatisfaction, and increased costs. Furthermore, a lack of integration between the warehouse management system and other software can lead to delays in the process due to manual data entry, lack of visibility into inventory levels, and difficulty tracking orders. To maximize efficiency, it is essential to have software that is integrated and can provide a unified view of operations.

Tips for Getting the Most Out of Your Pick, Pack and Ship Process

Unlock Your True Productivity By Investing in Automation

Investing in automation can help optimize your pick pack ship operations by reducing labor costs and increasing accuracy, efficiency, and productivity. Automation solutions can help streamline processes, reduce human error, and provide real-time visibility into the status of orders. Automation also allows you to scale operations more quickly and easily and operate with fewer staff members. Additionally, integrating automation into your operations can help you meet customer demands and ensure order accuracy, as well as provide a seamless customer experience.

Harness the Power of Efficiency with Software Solutions 

Using inventory management and fulfillment software solutions to optimize pick pack ship operations can help streamline the process and ensure accuracy. Software solutions can provide visibility into inventory and distribution processes, enabling operations teams to make better decisions that save time, maximize efficiency, and reduce costs. Automated systems can also help to reduce manual errors, automate tedious tasks, and improve customer service by providing real-time tracking information. Additionally, software solutions can help to optimize warehouse space, improve the accuracy of ordering and shipping, and provide insights into customer buying trends. Ultimately, software solutions provide the tools necessary to help create a more efficient and cost-effective pick pack ship operation.

Streamline Picking and Order Packing with Thoughtful Warehouse Setup

A thoughtful warehouse setup can significantly optimize order fulfillment operations by helping to streamline processes and reduce errors. The reduction of warehouse worker transit time should be a high priority. Directed picking might give order pickers the shortest route to take for any given order, but that can still mean long overall distances are involved. By locating items with the highest turnover closest to the packing station and grouping items often ordered together, noticeable time can be saved. 

By implementing a well-thought-out layout, such as using aisles, zones, and shelves in the warehouse to organize merchandise, it will be easier to quickly locate inventory. Additionally, utilizing an automated inventory tracking system can help to reduce the amount of time spent on manual inventory counts. Moreover, implementing a pick-to-light system can improve accuracy and efficiency by providing visual cues to quickly identify the right product to pick. Finally, using a conveyor system or automated guided vehicles can help speed up the order fulfillment process.

Outsource Pick/Pack/Ship Services to a Fulfillment Provider 

Outsourcing pick and pack services to a fulfillment warehouse can help optimize operations by streamlining the entire process. Fulfillment providers are experts in their field and know the most efficient way to optimize the process, resulting in fewer mistakes, faster delivery times, and overall improved customer experience. Fulfillment providers also offer services such as order tracking, inventory management, and customer service support, which further streamline the process and make it easier for businesses to manage their operations. Additionally, outsourcing to a fulfillment provider can help businesses save money by eliminating the need to hire and train additional staff and purchase specialized equipment.

Take Full Command of Your Pick, Pack and Ship Process with SkuNexus

Any management software system must have the flexibility to meet your needs, not the other way around. When it comes to deciding on software to manage your warehouse fulfillment operations, think about not only your most pressing current issues, but also how you might like to be doing things 1, 3, and 5 years from now.

For example, the implementation of directed picking might be a vast improvement over current manual processes, but is the system sophisticated enough to run complex strategies that you and your team might need to employ as the company grows?

Automation should be at the forefront of any solution you consider. The reduction of manual processes within pick and pack operations is paramount, from improving picking accuracy to saving employee time to reducing material waste by eliminating decision-making during packing.

The future expansion (volume of orders, warehouses, sales channels) is something else to think about. Not all platforms are created equal. As your business grows, the ability to easily and seamlessly integrate that growth with your software will let you focus on other things and save countless time, frustration and headaches.

Do not overlook the team behind the software, either. A management software provider should be a consultant and trusted partner, not just another vendor you use. 

At SkuNexus, we take great pride in not only designing flexible order fulfillment software systems that grow alongside our customers, but also in the strength of those relationships. Our dedicated support and development team works closely with clients to discuss ideas, provide advice, and help tailor the software to fit their needs.

If you would like to learn more about how SkuNexus can help your eCommerce business, please schedule a demo.