Two-stage picking, also known as batch picking or “two-stage order picking”, is an efficient method in logistics that aims to optimize order processing and speed up picking processes. In this process, several customer orders are combined into a so-called batch and processed in two successive stages.

In the first stage, items are picked one by one, with the items being picked in the required total quantity. Combining several orders enables more efficient use of warehouse resources and reduces the effort required to pick each individual order separately. This leads to higher productivity and improved utilization of warehouse staff.

The second stage is order-based sorting, in which the previously picked items are distributed to the individual customer orders. An automatic sorter is often used here, which sorts the items according to specific criteria such as order number, destination or product type. The use of an automatic sorting system further speeds up the process and minimizes the risk of errors when assigning the items to the respective orders.

One advantage of two-stage picking is that it is particularly suitable for companies that process a large number of smaller orders. By bundling several orders into batches and using automatic sorting systems, the throughput time can be significantly reduced. This results in faster delivery of goods and increased customer satisfaction.

There is also a variant of two-stage picking known as “shortened two-stage picking”. In the first stage, the items are not picked item by item but order by order and then sorted directly. This method is particularly suitable for companies with a high volume of similar orders.

To summarize, two-stage picking (batch picking) is an innovative logistical process that increases the efficiency of order processing. By grouping customer orders into batches and using automated sorting systems, companies can optimize their picking processes, reduce lead times and improve the overall performance of their logistics system.

Source: logipedia / Fraunhofer IML