Order Picking Checklist: 15 Points for an Error-Free Warehouse

Use this checklist to assess your picking process

This checklist helps you systematically assess the state of your order picking process. Go through all 15 points and note where there is room for improvement. The more points you can check off, the stronger your picking process is.

Warehouse layout

1. Does every product have a fixed, labeled picking location?

Products without a fixed location lead to search time and errors. Assign each product an unambiguous location with a consistent coding system (for example, aisle-rack-level-bin).

2. Are fast movers in the most accessible positions?

Perform an ABC analysis: the 20% of products that are picked most often (A products) should be at eye level, close to the packing station. This can significantly reduce total walking time.

3. Are the location labels clearly visible?

Labels should be large enough, placed in a logical spot, and readable in any lighting condition. Consider QR codes at locations to enable digital verification.

Picking process

4. Is every picked product verified?

Without verification — such as barcode scanning — you only discover errors when they reach the customer. Scan verification flags a wrong product the moment it is picked.

5. Do you have insight into your error rate?

If you don't know how often errors are made, you can't improve in a targeted way. Measure the number of incorrect orders relative to the total, and analyze where the errors occur.

6. Are walking routes optimized?

Employees who crisscross through the warehouse lose time. A logical route (S-pattern or return route) can shorten the walking time per order. Read more about optimizing order picking.

7. Do employees work with digital or paper pick lists?

Digital pick lists offer real-time updates, location guidance, and scanning capabilities. Paper lists offer none of these advantages and are a common source of errors.

Staff

8. How long does onboarding new employees take?

If onboarding takes weeks, you are missing a system that guides employees. Digital location guidance enables new colleagues to work productively from day one.

9. Is there a standard working method in place?

Without a standard working method, every employee picks in their own way. Document the process — or use software that enforces the standard working method.

10. Can you scale up quickly during busy periods?

During peak periods, you need to be able to deploy extra capacity quickly. Systems that charge per user make this expensive. A pay-per-pick model is more economical with fluctuating volumes.

Technology

11. Do you have real-time insight into order status?

Can you see at any moment which orders are open, in progress, or completed? Real-time insight is essential for customer communication and planning.

12. Are turnaround times measured?

Do you know how long it takes from order to ready-to-ship? Without this data, you can't identify bottlenecks or measure improvements.

13. Do you need hardware that locks you in?

Handheld terminals are expensive to purchase and maintain. Browser-based solutions that work on a regular smartphone offer the same functionality at a fraction of the cost.

14. Can you easily switch or cancel?

Long-term contracts and high implementation costs make you inflexible. Look for a solution without fixed contracts that you can use whenever it suits you.

Data and optimization

15. Do you use data to improve your process?

Digitizing your picking process automatically generates data: turnaround times, error rates, performance per employee, and more. But collecting data is only useful if you also act on it. Schedule regular evaluations and adjust your layout or process based on the insights. Read more about warehouse digitization.

How do you score?

• 12-15 points: Your picking process is well set up. Focus on continuous optimization with data.
• 8-11 points: There is room for improvement. Start with the points that have the biggest impact: verification, digital pick lists, and location layout.
• 0-7 points: There is significant potential for improvement. Consider order picking software that addresses multiple points at once.

Further reading

• Order picking software — All features of OrderPiQR
• 5 common picking errors — and how to prevent them
• Batch, wave, and zone picking explained
• Warehouse layout for your online store