In system-directed picking, the WMS assigns pick routes and tasks to workers based on real-time priorities such as courier cut-offs, order age, zone congestion, and picker location. This intelligent orchestration removes guesswork, dramatically boosting throughput and accuracy.

For example, orders due for DPD Next Day by 3 PM are automatically prioritised and routed for picking before orders with longer SLAs. The system continuously optimises picker paths, ensuring maximum efficiency whilst meeting all service commitments.

How System-Directed Picking Transforms Operations

Without system direction, pickers often choose their own routes, select orders randomly, or follow paper lists that don't adapt to changing priorities. This leads to missed deadlines, inefficient travel paths, and inconsistent productivity.

System-directed picking revolutionises this process:

Real-Time Task Assignment When a picker completes a task, the system instantly assigns the next optimal pick based on:

• Current picker location

• Urgent order priorities

• Congestion at pick faces

• Batch picking opportunities

• Equipment being used (trolley, forklift, etc.)

Intelligent Route Optimisation The system calculates the most efficient path through the warehouse, considering:

• Minimising travel distance

• Avoiding congested aisles

• Grouping picks by zone

• Weight distribution on trolleys

• Pick sequence for packing efficiency

Dynamic Priority Management As deadlines approach or new urgent orders arrive, the system automatically reshuffles pick sequences to ensure critical orders complete first.

Common Challenges and Practical Solutions

The "Experienced Picker" Resistance

The Challenge: Veteran pickers often believe they know the best routes and resist system direction. "I've been picking these aisles for years" is a common objection.

The Solution: Show, don't tell. Run parallel trials comparing system-directed vs traditional picking. Share metrics showing:

• Reduced walking distances

• Improved pick rates

• Better on-time performance

• Less physical fatigue

Most sceptics become advocates once they experience the benefits firsthand.

Balancing Efficiency vs Service

System algorithms might prioritise the most efficient pick path, potentially delaying urgent orders. This creates tension between operational efficiency and service level achievement.

Modern systems resolve this through multi-factor optimisation:

• Time-based priority weighting

• Customer tier considerations

• Courier cut-off buffers

• Dynamic re-routing capabilities

Technology Adoption Hurdles

Common Concerns:

• "The system is too complicated"

• "What if devices fail?"

• "We'll lose flexibility"

Solutions:

• Intuitive interfaces requiring minimal training

• Offline capability for device failures

• Override options for exceptions

• Gradual rollout to build confidence

Business Impact of System-Directed Picking

The shift to system-directed picking delivers measurable improvements across key metrics:

Productivity Gains Operations typically see 25-40% improvement in pick rates through optimised routing and reduced decision time. Pickers spend more time picking and less time walking or thinking about what to do next.

Accuracy Improvements System direction reduces pick errors by presenting clear, step-by-step instructions. Integration with scan-to-verify processes ensures the right items go to the right orders. This accuracy is crucial for maintaining high order accuracy rates.

Service Level Achievement Dynamic prioritisation ensures time-sensitive orders always get picked first. This reliability is essential for meeting delivery SLAs and maintaining customer satisfaction.

Scalability System-directed picking scales effortlessly. New staff become productive quickly by following system instructions. Seasonal workers need minimal warehouse knowledge to achieve veteran-level performance.

Key Metrics to Monitor

Track these KPIs to measure system effectiveness:

• Picks per Hour - Individual and team productivity

• Travel Distance per Pick - Route optimisation effectiveness

• Order Cycle Time - From release to dispatch ready

• Priority Order Performance - On-time completion rates

• Pick Accuracy - Error rates pre/post implementation

• Picker Utilisation - Active picking time vs total shift time

These metrics guide continuous improvement and rule refinement. Explore comprehensive warehouse KPIs for broader operational insights.

Frequently Asked Questions

How quickly do pickers adapt to system direction?

Most pickers become comfortable within 2-3 days. The key is starting with simple picks and gradually introducing complexity. Younger workers often adapt immediately, while veterans may need more support and evidence of benefits.

Can the system handle different picking methods?

Yes, system-directed picking enhances all methodologies:

• Discrete picking: Optimised single-order routes

• Batch picking: Intelligent multi-order grouping

• Zone picking: Coordinated zone assignments

• Wave picking: Synchronised wave execution

What happens during system downtime?

Modern cloud-based systems rarely experience downtime. However, contingency plans include:

• Cached pick lists on devices

• Backup paper pick lists for critical orders

• Manual priority boards

• Supervisor-directed picking

How does it integrate with voice or pick-to-light?

System-directed picking complements other technologies. The WMS provides the intelligence while voice picking or pick-to-light systems deliver instructions. This combination maximises both efficiency and accuracy.

Integration Considerations

Implementing system-directed picking requires:

Technical Infrastructure:

• Warehouse management software with picking optimisation

• Mobile devices (handhelds, wearables, or voice units)

• Reliable WiFi coverage throughout picking areas

• Barcode/RFID scanning capability

Operational Prerequisites:

• Accurate location mapping

• Defined pick faces and paths

• Clear priority rules

• Trained supervisors for exception handling

Data Requirements:

• Real-time inventory visibility

• Order priority attributes

• SKU dimensions and weights

• Historical pick time data

Change Management:

• Staff training programme

• Performance monitoring tools

• Incentive alignment

• Clear communication of benefits

Alternative Approaches to Pick Management

Paper Pick Lists

Traditional printed lists in pick sequence. Simple but static - can't adapt to changing priorities or optimise across multiple orders. No real-time visibility or performance tracking.

Picker-Chosen Routes

Experienced staff select their own orders and routes. Results vary dramatically between individuals. Difficult to maintain service levels or train new staff.

Basic WMS Picking

System generates pick lists but doesn't optimise routes or dynamically assign tasks. Better than paper but misses significant efficiency opportunities.

Full System-Directed Picking

Intelligent, real-time task assignment with route optimisation and priority management. Consistent high performance regardless of staff experience. Essential for 3PL fulfilment providers and ambitious eCommerce retailers.

Next Steps: Revolutionise Your Picking Operation

Understanding your picking potential starts with analysis:

• Current pick rates and accuracy levels

• Service level achievement rates

• Picker travel distances and patterns

• Training time for new staff

Schedule a Consultation to discover how system-directed picking could transform your warehouse productivity and service levels.

Related Topics: System-Directed Putaway | Priority Rules Engine | Digital Picking