Warehouse Pick Path Optimization: How to Reduce Fulfillment Time and Costs

Executive TLDR

A warehouse pick path is the route a picker follows to retrieve items for an order.

Optimized pick paths reduce travel time, improve accuracy, and lower labor costs.

Strategic warehouse layout, slotting optimization, and WMS technology are critical to improving pick efficiency.

If your fulfillment operation needs faster, more accurate order processing,
contact Product Fulfillment Solutions to streamline your warehouse operations.

Table of contents

• What Is a Warehouse Pick Path?
• Why Pick Path Optimization Matters
• Common Warehouse Picking Methods
• Strategies to Optimize Pick Paths
• Technology’s Role in Pick Optimization
• How a 3PL Optimizes Warehouse Operations
• Warehouse Pick Path FAQs

What Is a Warehouse Pick Path?

A warehouse pick path is the sequence and route a warehouse associate follows to collect items for customer orders. Since walking time often accounts for over 50% of warehouse labor costs, optimizing the pick path can significantly improve efficiency.

The goal is simple: reduce unnecessary travel while maintaining high order accuracy.

Why Pick Path Optimization Matters

• Reduces labor costs
• Improves order accuracy
• Increases order processing speed
• Enhances same-day and next-day shipping performance
• Supports scalable growth

Without optimization, pickers may double back through aisles, create congestion, and waste valuable time.

Common Warehouse Picking Methods

Single-Order Picking

Each order is picked individually. Simple but inefficient at scale.

Batch Picking

Multiple orders are picked simultaneously to reduce trips through the warehouse.

Zone Picking

Pickers are assigned specific warehouse zones and pass orders between zones.

Wave Picking

Orders are grouped and picked during scheduled intervals based on shipping deadlines.

Strategies to Optimize Pick Paths

1. Smart Slotting

High-volume SKUs should be placed in easily accessible, high-traffic areas to minimize travel distance.

2. Data-Driven Layout Design

Analyze order history to determine which products are frequently purchased together and position them strategically.

3. Minimize Cross-Traffic

Design aisles and workflows to reduce congestion and improve safety.

4. Implement Directed Picking

Use warehouse management systems to assign optimized pick routes dynamically.

Technology’s Role in Pick Optimization

Modern warehouse management systems (WMS) automatically calculate the most efficient pick path based on order volume, SKU location, and warehouse layout.

Barcode scanning, mobile picking devices, and real-time inventory visibility reduce errors and improve throughput.

At Product Fulfillment Solutions, our
real-time reporting technology
ensures complete visibility into inventory and order flow.

How a 3PL Optimizes Warehouse Operations

Optimizing pick paths requires experience, data analysis, and infrastructure. A professional 3PL can provide:

• Strategically designed warehouse layouts
• Continuous SKU slotting optimization
• Advanced WMS integration
• Labor efficiency improvements
• High-volume order processing capabilities

From our
Cincinnati, Ohio fulfillment center,
we help ecommerce and B2B brands reduce costs while improving speed and accuracy.

If slow picking is limiting your growth, it’s time to fix the root cause.

Warehouse Pick Path FAQs

What is a warehouse pick path?

A warehouse pick path is the route a picker follows to retrieve products for order fulfillment.

Why is pick path optimization important?

It reduces labor costs, improves accuracy, and speeds up order processing.

How do you improve warehouse pick efficiency?

By optimizing warehouse layout, implementing smart slotting, and using WMS technology for directed picking.

Can a 3PL improve pick performance?

Yes. A 3PL uses advanced systems, optimized layouts, and trained teams to improve efficiency and reduce fulfillment costs.