Defining batch and wave picking
**Batch picking** groups multiple orders into a single pick trip. A picker collects items for 10–50 orders simultaneously, then sorts them at a pack station. This minimizes walking by consolidating picks from the same locations. **Wave picking** releases orders in timed batches aligned to carrier pickups or shift schedules. Waves coordinate pickers, packers, and shippers so completed orders hit the dock together. The two strategies solve different problems and often work together.
When to use batch picking
Batch picking excels when orders share common SKUs and your facility has long pick paths. Ideal scenarios: single-item orders from a catalog, subscription boxes with overlapping products, or promotional campaigns with concentrated demand. Start with batches of 10–20 orders and scale based on cart capacity and picker experience. Batch picking alone doesn't guarantee carrier compliance—you still need to manage timing.
When to use wave picking
Wave picking shines when you have strict carrier cutoffs, multiple shipping priorities, or separate teams for picking and packing. Release waves 2–3 hours before carrier pickup, sized to match labor capacity. Monitor wave progress on dashboards and escalate late picks before they miss cutoffs. Waves work well for B2B orders with scheduled delivery windows or retail compliance requirements.
Hybrid strategies
Most high-volume warehouses combine both methods. Define waves by carrier cutoff or priority tier, then create batches within each wave for efficient picking. Example: Release a FedEx Express wave at 10 AM containing 200 orders. Batch those orders into 20 pick carts of 10 orders each. Pickers complete batches; packers process orders as they arrive at the station. The wave ensures timing; the batch ensures efficiency.
Measuring success
Track these KPIs for picking strategy optimization: **Lines per hour** (target 80–120 for batch picking). **Wave completion rate** (target 98%+ on-time). **Pick accuracy** (target 99.5%+ with scanning). **Walking distance** (measure before and after changing strategies). Review metrics weekly and adjust batch sizes or wave timing based on patterns.
Guide
Batch Picking vs Wave Picking
Understand when to deploy batch or wave picking so your team hits throughput targets without chaos.
When to use batch
Batch picking shines when orders share many SKUs or zones. Operators stay in one aisle longer and tote multiple orders at once.
Review the batch picking playbook for implementation details.
When to use wave
Wave picking coordinates large order volumes around carrier cutoffs and labor availability. Waves release work in controlled bursts.
Check the wave picking playbook to design wave templates.
Throughput examples
A batch team handling 50 mixed orders may average 2.5 lines per minute, while a wave team targeting carrier cutoffs completes 200 orders per wave with three pickers.
Blend methods: start the day with waves, then switch to batches for late-arriving DTC orders.
Selecting a method
- Map SKU commonality and order profiles.
- Audit carrier pickup schedules and labor mix.
- Run pilots with productivity tracking to measure gains before rolling out.
FAQs
Can we run batch and wave together?
Yes. Use separate workflows and dashboard filters so teams stay organized.
How do we transition between methods?
Train leads on both processes, then adjust schedule blocks as data reveals peaks.
What metrics matter most?
Track lines per hour, travel distance, and on-time shipment rates to understand impact.
Match picking to demand
Use LollipopWMS analytics to choose the method that keeps shelves clear and customers happy.