Cluster picking

What is cluster picking?

Cluster picking is a warehouse order fulfillment method where operatives use multi-compartment carts or totes to pick items for several orders in a single trip.

Cluster picking vs batch picking

Cluster picking and batch picking are both types of cart picking, but are different. Cluster picking differs from batch picking in how items are organized during the pick.

Batch picking collects all items into a single container, requiring a separate sortation process to distribute products to individual orders.

Cluster picking sorts items into their final orders during picking, eliminating the sortation step and associated handling time.

Cluster picking works best for operations with moderate order sizes and sufficient product overlap between orders. It is often used alongside wave planning, which determines when groups of orders are released for fulfillment. Batch picking works best for very small or very large orders.

The benefits of warehouse cluster picking

Cluster picking minimizes travel time and increases order throughput as operatives can fulfill multiple orders in one trip.

As cluster picking incorporates sorting into the picking process, it’s faster, more accurate and more efficient.

How WMS handles cluster picking

The warehouse management system (WMS) groups compatible orders into clusters based on factors including order size, delivery zones and product overlap. It selects orders containing products from similar warehouse areas to minimize travel distance while ensuring the combined pick volume fits within cart capacity limits.

Multi-compartment carts contain segregated spaces for each order in the cluster, often using numbered slots or color-coded containers. As operatives travel through the warehouse, the WMS directs them to each pick location and indicates which cart compartment receives each item through visual displays, voice prompts or light indicators integrated with the cart.

Pick verification occurs as operatives scan items and the WMS confirms correct placement into designated order slots. This real-time validation prevents the sorting errors common in traditional batch picking.