The Cost of Walking the Warehouse Twice
The most expensive asset in your warehouse is not the inventory. It is the Human Legs. Walking accounts for 50-70% of a picker's time. Only 10% is actual "Picking."
The "Spaghetti" Route
If your bin numbering is chaotic (e.g., sorted by Product ID instead of Walk Sequence), your picker is doing a zigzag. Aisle 1 -> Aisle 10 -> Aisle 2 -> Aisle 9. This is burning cash.
The Z-Pick
Your WMS must enforce a "Z-Pick" or "S-Pick" route. Start at Aisle 1. Snake through to the end. End at Dispatch. Never, ever, send a picker back to the start.
Optimization vs Reality
"But I forgot an item!" If a picker misses a scan, most systems make them go back immediately. Don't. Let them finish the route. Flag the error. Have a "Sweeper" fix the exceptions. Sending a picker back 50 meters breaks their rhythm and kills the batch efficiency.
Frequently Asked Questions
What is a Pick Path?
The calculated sequence of locations a picker visits. It should minimise total travel distance.
How do I optimise my layout?
Place high-velocity items (fast movers) near the dispatch/packing area (The "Golden Zone"). Place slow movers at the back or high up. This reduces the average walk per order.
Does batch picking reduce walking?
Yes. Picking 10 orders at once means you walk the aisle once to get 10 items, instead of walking it 10 times.