Geschreven door Bjorn Hutgens, Manager sales
Geschatte leestijd: 5 minutes
Busy warehouses need order picking processes that keep pace without creating unnecessary mistakes. When order volumes grow, small inefficiencies on the warehouse floor can quickly affect packing, outbound flow and customer satisfaction. Adding more manual checks may seem like the safest answer, but it can also slow operators down. A stronger approach is to make the picking process clearer, more guided and better connected to the wider warehouse flow.
ARCO Solutions develops order picking systems as part of complete intralogistics flows, where hardware and software work together to support the operation
In this blog, you will learn:
- How to recognize where your current picking process loses control
- Which order picking methods can support operators on the floor
- What to assess before choosing an order picking system that can scale
Order picking performance starts before the pick
Order picking problems often become visible at the packing stage, but the cause usually starts earlier. If stock information is unreliable or product locations are unclear, operators have to solve issues while they are already picking. That creates friction. Operators may spend more time searching, checking or correcting. Even experienced teams can lose pace when the process depends too much on manual interpretation.
A good order picking system reduces this uncertainty. It gives operators clearer instructions and helps guide each action in the flow. The goal is to make the process easier to follow, without adding unnecessary steps.
Why extra checks do not always improve the process
Manual checks can be useful, but they should not become the main way to control quality. If every order line needs extra attention, the picking process becomes slower and harder to manage.
The better question is where the mistake starts. Is the issue caused by unclear instructions? Are operators walking too much? Does replenishment arrive too late? Or is the picking method no longer suited to the order profile? When the root cause is clear, automation can support the process at the right point. That can mean visual guidance, mobile picking support or a different way to divide orders across workstations.
Order picking systems are broader than pick-to-light
Pick-to-light is a strong option for many picking environments, but it is only one part of the order picking landscape. ARCO’s order picking solutions include several methods, depending on the flow and the type of operation.
The right choice depends on how orders are built and how goods move after picking. A system that works well for small-item picking may be less suitable for a process with larger products or different batch logic.
Guided picking helps operators stay in flow
Guided picking supports operators during the task itself. Instead of relying on printed lists or memory, the system shows what needs to happen next.
That can improve order picking accuracy without turning the process into a series of manual checks. Operators receive clearer guidance, while the system records activity and keeps the process connected to the software layer. This is especially useful when product ranges grow or operators need to handle different order types during the same shift. The process becomes easier to learn and easier to control.
What to assess before choosing an order picking system
Before choosing a new order picking system, it is important to understand how the current flow works. Technology should fit the operation, not the other way around.
A practical assessment should include:
- Where picking errors or delays occur most often
- How operators currently receive picking instructions
- Whether stock information is reliable at the pick location
- How much time operators spend walking or searching
- Which order profiles occur during normal days and peak periods
- How picked goods move towards packing
- Whether WMS or WCS software can support the desired flow
- How the solution can scale when volumes increase
This helps determine whether the best fit is pick-to-light, mobile picking, pick-to-cart or another setup.
Why order picking must connect to the wider warehouse flow
Order picking should never be designed as an isolated process. It depends on what happens before the pick and what happens after it. If storage locations are poorly structured, picking becomes harder. If replenishment is not aligned with demand, operators lose time. If packing cannot keep up, picked orders wait at the end of the line.
ARCO approaches order picking as part of a connected intralogistics process. Its systems are designed to connect with storage, transport lines and packaging processes, supported by software and data. That connected view matters because the value of an order picking system is not only measured at the picking location. It should improve the flow towards outbound.
Checklist: improving order picking without slowing operators
Use this checklist when reviewing your current picking process:
- Identify the process steps where operators lose most time
- Check whether instructions are clear enough during the pick
- Review whether product locations match the order profile
- Compare manual checks with guided picking options
- Assess whether pick-to-light fits your volume and layout
- Look at mobile picking if flexibility is important
- Review the handover from picking to packing
- Include software integration early in the decision
- Make sure the solution can support future growth
A strong order picking system should make the operator’s work clearer. It should reduce unnecessary decisions and support a smoother warehouse flow.
How ARCO Solutions supports order picking automation
Improving order picking requires more than adding a single tool. It starts with understanding the flow, the operator task and the connection with the rest of the warehouse. ARCO Solutions develops order picking systems that fit the specific process. Depending on the operation, this can include pick-to-light, pick-to-cart, put-to-wall/light, mobile order picking or supporting modules such as print and labelling units.
By looking at order picking as part of the full intralogistics process, ARCO helps companies choose a solution that supports accuracy, operator flow and scalability. Do you want to improve your order picking process without slowing down your operators? Contact ARCO Solutions to discuss which order picking system fits your warehouse flow.
Want to know more?
Feel free to get in touch – we are more than happy to discuss all the possibilities, together.
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Will you challenge us?
Our technical experts are always looking for a new challenge. Has your company encountered problems for which there is currently no solution? Here at ARCO, we are known for delivering innovative, customized solutions.
- Our knowledge is your knowledge
- We never stand still
- Going beyond the best solution
What our customers say about us
“We saw great commitment and determination. ARCO didn’t leave until the system was running. That shared drive made the cooperation truly enjoyable.”
“ARCO delivered an automated solution that integrates seamlessly with our pick line. Their dedicated approach and smooth execution made it a partnership worth repeating.”
“Our cooperation with ARCO was excellent. Where we previously relied on manual and labour-intensive processes, we now have a fully automated system that makes our production far more efficient.”
“ARCO responded quickly and showed great creativity in the design and test setups. Our close cooperation made the successful implementation of the new packaging line possible.”
‘ARCO’s weighing line has had a major impact on our production. Our new system cuts product losses by up to 6%. It was a successful project and a rewarding collaboration.’
“ARCO is a no-nonsense partner that thinks in practical, affordable solutions. With their expertise, they build strong and efficient intralogistics systems. We look forward to working together again.”
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FAQ
What is an order picking system?
An order picking system supports operators in selecting the right products for an order. It can use visual guidance, mobile instructions or software-driven workflows.
Is pick-to-light always the best solution?
No. Pick-to-light can be effective, but the right solution depends on your order profile, layout and required flow.
How does guided picking help operators?
Guided picking gives operators clearer instructions during the task. This reduces manual interpretation and helps keep the process moving.