In brief
An order picking system assembles partial quantities from an available assortment according to orders. Its performance results from provision, movement, picking, checking, transfer, information and labour—not from an isolated equipment choice.
What belongs to an order picking system?
The established VDI 3590 framework treats order picking as an integrated system of material, information and organisational functions. Current planning adds today's requirements for ergonomics, software, sensors and automation to that foundation.
VDI 3657:2025-09 covers physical and mental workload as well as digital assistance. VDI 4481:2019-04 complements it with labour-requirement calculation.
Order and item profiles before technology
| Data area | Examples | Planning impact |
|---|---|---|
| Items | Dimensions, weight, turnover, hazardous goods, batches | Storage zone, picking method and aids |
| Orders | Lines per order, units per line, time windows | Batching, zones, sorting and peak performance |
| Inventory | Coverage, seasonality, reserve, replenishment | Provision quantity and replenishment strategy |
| Labour | Shifts, skills, performance variability | Workstations, staffing and ergonomics |
| Quality | Error tolerance, identification, traceability | Checks, assistance and system guidance |
Six design elements
- Provision: static or dynamic, goods-to-person or person-to-goods.
- Movement: walking, driving, conveying or automatic feeding.
- Picking: manual, assisted or automated, including gripping and handling conditions.
- Checking: identification, quantity, weight, scanning and traceability.
- Transfer and consolidation: order carriers, buffers, sorting and shipping handover.
- Information: WMS order, dialogue guidance, status, exceptions and feedback.
Compare typical system families
| System family | Strengths | Check carefully |
|---|---|---|
| Person-to-goods | Flexible, low technology threshold | Travel share, ergonomics and peak staffing |
| Goods-to-person | Short reaches, high space utilisation | Replenishment, sequencing and availability |
| Zone picking | Specialised areas and parallel work | Handover, balancing and consolidation |
| Automated picking | Repeatability and low walking effort | Item suitability, exceptions and economics |
Size for peaks, not averages
Design should use order lines and picks per time unit, not merely order counts. Peak profiles, breaks, replenishment, order mix, travel, failures and shift handovers are considered separately. Required workplaces and staff follow from effective rather than theoretical performance.
Ergonomics and digital assistance
Reach height and depth, load weight, repetition, posture and travel influence both performance and health. Digital assistance can reduce search and checking effort but creates visual, acoustic and cognitive demands of its own. Planning therefore tests not only technical function, but whether people can operate the system safely and reliably throughout a shift.
Technical basis
- VDI 3590 Parts 1 and 2, fundamentals and system selection for order picking.
- VDI 4481:2019-04, determination of labour requirements in order picking.
- VDI 3657:2025-09, ergonomic design of manual order picking systems.
For application, see warehouse planning, warehouse technology and warehouse management systems.