Pick Path Optimization

What is pick path optimization?

Pick path optimization uses algorithms to determine the most efficient sequence and route for warehouse operatives to retrieve items.

What are the benefits of warehouse pick path optimization?

Pick path optimization minimizes the travel distance and time required to complete order fulfillment.

This improves productivity, reduces warehouse congestion and lowers the risk of tiredness and injury.

How picking route optimization works

Picking route optimization can be carried out using a warehouse management system (WMS).

The WMS evaluates all items in a pick assignment and calculates optimal collection sequences considering facility layout, aisle configurations and product locations.

Common pick path optimization strategies include:

• S-shaped (or ‘serpentine) routing where operatives move down one aisle and back up the next

• Return routing where operatives enter and exit from the same aisle end

• Largest-gap routing where operatives skip aisles with no required picks

Zone-based optimization is also a solid strategy in large warehouses. This divides warehouses into districts, assigning operatives to specific areas where they develop location familiarity, reducing search time. The WMS coordinates handoffs between zones for multi-zone orders, balancing workload across areas while maintaining the efficiency gains from specialized picker assignments.

Dynamic path calculation adjusts routes in real time based on warehouse conditions. If congestion occurs in specific aisles or equipment failures block access, the system reroutes operatives around obstacles.