Case Picking: What Is It and The Purpose in Warehousing

Case picking is the process of selecting individual cases or cartons of products from inventory, typically containing multiple units of SKUs. This method allows warehouses to fulfill orders requiring specific quantities of items.

The “case” is a box that contains a certain number of SKUs. Case picking is often combined with palletization or pallet building where individual cases selected from inventory are grouped and arranged on pallets, however, cases can also be picked on trolleys or conveyors.

When is Case Picking Used?

Case picking is used in distribution centers to move cartons of items to retail or e-commerce fulfillment centers when orders require a specific quantity of items that can be handled and shipped in boxes. It is commonly employed for B2B shipments, such as "replenishments" to small shops. These shops typically order several products but not in full pallet quantities, making case picking an ideal solution.

Ways of Case Picking:

Case picking can be combined with other order-picking methods such as:

1. Single Picking: picking 1 case at a time from the shelf. This method is straightforward but can be time-consuming for large orders.
2. Batch Picking: Pickers gather cases for multiple orders all at once. This method increases efficiency by reducing travel time between picks.
3. Wave Picking: Multiple orders are grouped together in "waves" and released at set intervals for picking. This method balances the workload and improves throughput.
4. Zone Picking: the warehouse is divided into zones. Each picker handles a specific section like a specialist. This method optimizes picker efficiency and reduces congestion in the warehouse.

The Best Picking Method for Your Warehouse

The optimal strategy depends on various factors such as warehouse layout, order profile, cut-off times, etc.

Recommendation: Simulate with a Digital Twin 

A digital twin—a virtual replica of your warehouse—allows you to simulate different picking strategies and assess their impact on picking distance and throughput time. By running “what if” scenarios, you can identify the most efficient strategies for your specific operations. This approach provides faster results and allows you to test solutions quickly, making it an increasingly relevant and popular tool in modern warehouse management.

Learn about optimizing pick and pack operations in warehousing.