Pick and Pack

Leverage a mobile barcode scanner to improve your productivity, efficiency, and accuracy using a pick and pack fulfillment process

Pick and Pack Fulfillment Batch Order Picking


“Pick and Pack” is another popular batch picking process and is a two-stage fulfillment process of picking and then packing (usually with different staff members picking and packing). Batch picking significantly reduces travel times and improves order picking productivity. Travel time can easily account for 50% or more of order picking hours. By combining orders into a single trip the time spent traveling is greatly reduced. With the pick and pack process, the barcode scanner will accuracy improvement by ensuring the corrects items are scanned and packed.

The first stage is the picking stage where the items to fulfill a batch of orders are pulled from the aisles and brought to a central location. The second stage is the order packing stage where orders are individually packed at a central location like a packing table. In this process, each item is scanned twice: first while picking in the warehouse, and again while packing on the central packing location.

Pick and Pack Stage #1 – Picking

Pick and Pack Fulfillment Batch Order Picking

In the first stage of pick and pack fulfillment process, a consolidated pick list consisting of a batch of orders is created to allow team members to efficiently pick the items from the warehouse. A consolidated pick enables picking of multiple orders at the same time. These orders are more effective for pickers traveling long distances within a warehouse or other pick area. By combining orders into a single trip the time spent traveling is greatly reduced.

Starting with the first aisle, pickers will utilize a cart and our integrated barcode scanner solution to guide the picker. As pickers grab and scans the first product off the shelf, the scanner will confirm they have picked the right product and will then guide them to the next location. This process is continued until everything on the consolidated picks list has been picked and is on the cart. Once picking is complete the cart is dropped off at a packing station for shipping. The picker can grab a new cart and empty totes and start the process over.

Pick and Pack Stage #2 – Packing

Pick and Pack Fulfillment Batch Order Picking

After the items have been picked and your packers are ready to begin packing orders, they only need to scan the order number from a packing slip and the barcode scanner will suggest the first item to be scanned and packed. When the correct product is scanned the packer will get a visual and audio confirmation and will be prompted for the next item. The process continues until all items have been scanned and packed.

With pick and pack, once scanning and packing is complete the status for the order is updated and inventory counts are adjusted. Since Finale scans items into and out of your warehouse you have true item-level visibility of your physical inventory with every stock operation stored to Finale giving you complete transparency. Each inventory change is made automatically as items are shipped and received, giving you an accurate inventory count.

Check out the video below to learn more about our Pick and Pack batch order picking solution.

Note shown in video: WiFI syncing also available

Pick and Pack Video Transcription

Hello, this is Mike, Finale Inventory. In this short demo, we’re gonna cover Pick and Pack, a fantastic batch order picking feature of our mobile barcode scanner. So let’s jump right in here. We’re gonna go here to the familiar Finale home screen. Now, what we’re talking about here is, you know, a condition where you may have a lot of orders to fulfill all at once and you don’t want to make individual trips into the warehouse for each individual order. You wanna somehow create a batch of orders and you wanna take all those orders and be able to create a consolidated pick list so that you go through the warehouse one time for all of the orders, pick all the items you need, and then you’re gonna pack them, okay? So, we call that Pick and Pack. So, for example, we’re gonna jump over to our ShipStation interface here.

So, I’m gonna be using the example here in ShipStation dashboard. We’ve got three orders sitting here waiting to be shipped. So, a common scenario would be, if you look, these three orders all have items on it. We’ve got one item on this one, two items on this one, and three on this one. So, they may have some commonalities. So, say, you know, the red card, maybe on all three orders, and then there’s something different on each of the other one. So, you’d want to only want to make one trip. So, ordinarily, a good way to do this is to create a batch. So, I’m just going to create and highlight all three orders. So, normally, what you could do then is say, “Print the packing slips.” So, if I said, you know, “Print the packing slips,” that would look something like this. So, you would each have a packing slip.

We’ve got a packing slip for the first order, it’s got the red card on it, for quantity one. We’ve got another order here with a black and a red card, and then the third order with a yellow, white, and red card. All right? So those are packing slips. So, what you would end up doing is printing those out and noticing here at the top corner, there is a barcode, in the upper right. That’s the barcode of the order ID. So, that’s going to drive the barcode scanner. So, the other thing that you commonly might try to do to assist yourself in doing this, is you might print a consolidated picklist. Now, at a ShipStation, it would look something like this. You see how it’s taking the three orders that I selected and it’s consolidating them and going, “You know what? You’re going to need to get three of the red cars and one each of these other ones to satisfy the three orders in total.” All right?

But you’re not going to have to do that, but I just want to give you that visual to see that’s exactly what our barcode scanner is going to do. So, once again, you would print your packing slips, it’s gonna give you the barcodes at the top. And then, of course, our goal here is the scanner is going to take care of this consolidated picklist for you, all right? So, let’s move on to what you would do next. So, you would…you know, this is where the Finale barcode scanner comes in. So, if you can see my live video there, you’re going to see where I’ve already printed out the packing slips. So, I’ve got three packing slips here, one for each of the three orders. It’s got a barcode in the upper right, that’s the barcode of the order ID, that’s going to assist the scanner.

So, I’m also going to bring up my scanner so you can see this. Now, we have a live link to my scanner. Now, our Finale mobile barcode scanner is wireless. It does not have to be connected to a computer. You can go anywhere you want in the warehouse. Now, you may see a cable in my video here, that’s just so that you can see this live link to it, okay? But that’s not required. So, what do we need to do? Well, we’re going to go to barcode scanning here in the background on the Finale Data Collector, I mean, on your Finale home screen. So, we’re going to connect to this docked mobile scanner. We’re going to update this scanner to make sure it’s got all the latest information and make sure it’s got those orders that came down from ShipStation into your account. So now that we’ve got those orders, we’re going to use this barcode scanner.

So, we’re going to choose, “Pick.” So, we would choose, “Pick.” Next thing, we want to do a batch. So, we’re not going to do basic, we’re not going to do wave, but we’re going to do pick and pack. So, we’re gonna choose pick and pack. Now, pick and pack is separating the two operations. First, you’re gonna pick, then you’re gonna pack. So, let’s do the picking part. So we’re going to choose Picking. Now, at this point, the scanner is asking you, “Hey, scan all the order IDs that you want in this consolidated pick or this batch.” Right? So, you can see it just says, “Scan the ID,” or, “Click here to choose.” Now, we could click here and it would actually show us all the orders that are in the system, but it’s a whole lot easier to use your packing slip barcodes.

So, that’s what we’re going to do. So, if you notice I’m going to grab my scanner at this moment in time, and, hopefully, kinda show you what I’m going to do here. So, we’ve got three packing slips and I’m just going to scan each one. So, we grab the first one and you notice the scanner says, “Orders: 1” We’re going to grab the second one, “Orders: 2.” Let’s grab the third one, “Orders: 3.” So that’s our three orders. So, we’re going to set these aside because we need to go to the warehouse. And over here in the background, you see my warehouse here, we’ve got some bins. So, it’s now time for me to start to pick. So, I’m going to hit the “Menu” button because that’s what it says to do. And then we’re going to say start picking. So, now that we’ve got start picking, this is where the mobile barcode scanner really is going to help your employees.

So, notice that it’s telling us what to do. You’ve got four items to go get. You’ve got to first get the yellow PVC cards and it tells us to get one of them, and it also, is telling us where to go, so it tells us to go into the warehouse to A04, and scan that location. So we’re going to find the A04, that’s the one right here in front of us. So, we’re going to scan that location. Now that we’ve scanned it, it says, “You need to get one of the yellow cards.” So, I’m going to reach in here and grab a yellow card. So, we’re gonna scan this yellow card. We’ve got that. Now, if you notice, I’ve got a plastic bin which is kind of representing my cart, so I’m gonna toss that in that cart. And now, if you look, the scanner’s telling us, “Okay, that’s all you need to do.”

So, it’s giving us some review of what should be left in there. In other words, the quantity of that item should be left in that location. But it’s also telling us, “Get ready. You need to go to A5 in the warehouse,” if you look there on the screen. So, I’m going to say, “Okay, I’m going to head to A5. That’s great. Thanks for telling me.” So, you need to scan the A5. So, we’re going to scan the next bin and it tells us we need to get a white card. So, I’m going to reach in here, I’m going to get a white card. So, I’m going to scan that white card. Scanner says, “Thank you.” And you should have four left and I can look in there and verify. Yeah, there’s four left. So, let’s go to A7.

So I’m going to say, “Okay, go to A7. We need to get a red card. So, A7 is right here. I’m gonna verify we’re at A7. And it tells us to get three red cards because that’s on more than one order. So, I’m going to reach in here and I’m gonna grab three. So, I’ve got three of these red cards, so I’m going to scan those. One, two, notice how the scanner is telling us to keep going. And hey, there’s one more. So, let’s get that third red item. All right, so it tells us we’re done with that and it also tells us, “Hey, get ready, you need to go to A9.” So, I’m going to say, “Okay,” there. I’m going to go to A9. Now, it tells us we need to get a black card. So, I’m going to scan the location A9, and it tells us, “Get one black card.”

Now, I’m going to demonstrate this. What if somebody put the wrong item? So, I’ve got a white card instead of a black card. And what if it was in that bin? And I’m not paying attention because, you know, there’s black cards and white cards in there. Let’s just play like I’m going to make a mistake here if that ever happens, right? So, I’m going to scan the wrong item. So, remember the scanner will keep your employees out of trouble. So, I’m going to say, “I didn’t mean to do that.” All right? I better undo that. So, I’m gonna go back and I’m gonna grab the black card like I’m supposed to. All right? So, let’s grab a black card. I’ve got that. Now, it tells me that was the last pick. Do you see that on the screen? So we’ve gotten all of the items for all three orders.

So, I’m going to say, “Okay.” It also tells us, “That is it. You have picked all the items for all three orders.” So I’m going to say, “Complete.” Now, at this moment, the scanner is telling us to enter a packing sub-location. So, the purpose here is the scanner has taken everything out of the warehouse, it has removed it from its original storage locations, and now, it’s going to transfer it to a centralized packing location for your employees to pack from. So, the goal here is, now they don’t have to walk in and out of the warehouse to pack each of the individual orders as they go through and pack them, they’re just going to pack them right off of the table. Or in my case, I’ve got this little packing bin where I removed everything from the warehouse. So, we’re going to call this my packing bin, all right now.

Okay. So, we would just use our packing sub-location barcode. So, I happen to have one on this bucket here, so I’m going to say, “Hey, make sure you put all of this into the pack sub-location.” So, that means that we would carry everything that we picked out of the warehouse to the packing area and they would then proceed to pack the orders from there. So, I’m going to say, “Okay,” here. Now, the scanner throws me back to the main menu. So, what are we going to do? Well, we’re going to go to the packing sub-location so that we can pack everything in this batch. So, we’d go right back to pick. We’d choose, “Pick and pack.” Now, we’re going to choose, “Packing.” So we would click on packing. Now, it says, “Hey, give me an order ID that you wish to pack.”

Now, all we’re going to do is I’m going to scan the very first packing slip. So, I’m going to scan the first one and it’s going to tell me, “Hey, you need to get a red card.” All right. And notice that it’s telling me to get it from the pack sub-location. So, that’s exactly what I’m gonna do. I’m gonna have to go in the warehouse to get it. I’m just going to get it right here from the packing sub-location. So, I’m going to scan that, put that with the order. It tells me, “Hey, that was the last pack. That was the last item that needed to be packed on that order. So, I say, “Okay.” That order is done. There’s nothing else to get for that order. It’s ready to go out the door. So let’s go, “Okay.” Now, it’s going to tell me, “Well, what else do you want to pack?”

So, I’m going to grab the second packing slips, I’m going to scan that. And it tells me to get another red card. So, I’m gonna reach into my little bin, grab a red card. Also, tells me that there’s one of those left in my pack sub-location. Yeah, okay. Thank you. Hopefully, that’s for the other order. So, it also tells me to get a black one because this order had both a red and a black. So, I’m going to get that. It tells me that was the last pick or pack for that order. So, it tells me, “Hey, you’re done with that order.” I’m saying, “Great, thank you.” I’ll send that out the door. So, then we’re down to our last order of that three. So, I’m going to scan that order ID. It tells me, “Get me a yellow card.” So, I’m gonna grab that yellow card.

Okay. What else do I need? It says here, “I need a white card.” So, let me get one of those, get that out of my bag. So, I got a white and then it tells me, what else? I should have another red one. There’s my last red card. So, that’s the last pack of that one. I’m done with that. I have just now successfully packed all three of those after I had picked everything in the warehouse. So, if I’m done here, I’m going to say, “Menu. Exit to the main menu.” I’m ready to throw this up to the cloud back into Finale. So, of course, you would come over here, dock your scanner, you’ll see all the information here.

So, you can see the transfers or the actual, you know, operations that are actually going on back here. So, if I was to show you here, you would see that we’ve got the picking part right here, which was transferring it from the original locations to the pack area, and then the three separate shipments on the packing of those. So, we’ll send those right up and we’re ready to go. So, that’s a quick example of how to use the Pick and Pack batch feature of the Finale mobile scanner. Now, of course, at this moment, what you normally would have done with these, is you would’ve printed shipping labels, and that would all have these all complete and ready to go.