Multi-Item Order Picking

In modern warehouses, speed and accuracy are everything. As order volumes increase and customers expect faster delivery, operations need smarter picking strategies that minimise movement, reduce handling, and streamline the path from shelf to shipment. One of the most effective methods for achieving this is multi-item order picking, supported by tmWare’s Multi-Item Order Picking system.

What Is Multi-Item Order Picking?

Multi-item order picking is a warehouse process where a picker collects products for multiple customer orders in a single pass through the warehouse. Instead of picking one order at a time, the picker gathers items in bulk and sorts them into separate order containers—usually totes—while moving through the picking locations.

This approach significantly reduces travel time and ensures that each product is handled as few times as possible.

The Core Principle: Touch the Item Only Twice

The fastest way to process high volumes of multi-item orders is to pick items in bulk and sort them directly into individual order totes mounted on a trolley. In this workflow:

1. Items are picked once from their storage location.
2. They are placed directly into the correct tote for that order.
3. The item is touched again only at the pack bench when it is packaged.

By limiting handling to just two touchpoints, warehouses dramatically improve efficiency while reducing the chances of errors.

Guided Picking with Scan Guns

tmWare enables this process through intelligent scan-gun guidance. The system directs pickers through the warehouse in an optimised route, grouping items by location so that everything in a specific area can be picked at the same time.

This reduces unnecessary walking and lowers overall footfall across the warehouse floor. Instead of travelling back and forth between aisles for individual orders, pickers complete multiple orders in a single efficient pass.

Intelligent Warehouse Awareness

A well-managed warehouse also understands where stock cannot easily be picked. For example:

• Locations that require a forklift or cherry picker
• Aisles temporarily blocked due to replenishment
• Pallet locations not suitable for manual picking

tmWare can account for these factors, allowing the system to guide pickers to suitable locations or provide alternative picking options.

Additionally, the system allows pickers to skip a pick, meaning they can collect larger quantities of an item in one go when it benefits efficiency.

Trolley-Based Tote Sorting

During the picking process, items are placed directly into labelled totes on a picking trolley. Each tote represents an individual order.

By sorting orders as they are picked, warehouses eliminate the need for a separate sorting stage. When the picking run is complete, the trolley already contains neatly organised orders ready for packing.

Efficient Handover at the Pack Bench

Once the picking run is finished, the picker simply drops the trolley at a dedicated pack bench.

Packers then:

1. Scan the tote assigned to an order.
2. Scan the items as they package them.
3. Print the shipping label directly from the system.

This scanning process acts as a built-in double check, ensuring accuracy before dispatch. If something is missing or incorrect, the system provides an audible alert, allowing the issue to be corrected immediately.

Taking Efficiency Even Further: Pack Pods

Even an already streamlined process can be improved.

One of the most powerful optimisations is positioning fast-moving products close to the pack bench, often referred to as pack pods. These are small, high-velocity stock zones placed within arm’s reach of packers.

With pack pods in place:

• Packers can pick and pack certain items without leaving their station.
• Travel time is eliminated for the most common products.
• Order throughput increases dramatically.

The result is a super-charged fulfilment process where picking, checking, and packing happen almost simultaneously.

The Result: Faster, Leaner Fulfilment

By combining bulk picking, trolley-based tote sorting, scan-guided routing, and intelligent packing workflows, tmWare’s Multi-Item Order Picking system creates a highly efficient warehouse operation.

Key benefits include:

• Reduced picker travel time
• Minimal product handling
• Higher picking accuracy
• Faster order throughput
• Built-in packing verification

For warehouses handling large volumes of multi-item orders, this approach delivers a powerful balance of speed, accuracy, and scalability.