{"id":33630,"date":"2026-08-03T10:04:35","date_gmt":"2026-08-03T09:04:35","guid":{"rendered":"https:\/\/stg-khh4l5.elementor.cloud\/pick-and-pack\/"},"modified":"2026-08-03T10:12:54","modified_gmt":"2026-08-03T09:12:54","slug":"preparation-et-emballage","status":"publish","type":"post","link":"https:\/\/stg-khh4l5.elementor.cloud\/fr\/pick-and-pack\/","title":{"rendered":"Pr\u00e9paration et emballage : le guide complet des processus, m\u00e9thodes et logiciels d'entrep\u00f4t"},"content":{"rendered":"<p><strong>Le \u00ab pick and pack \u00bb d\u00e9signe le processus d'entrep\u00f4t consistant \u00e0 s\u00e9lectionner des articles individuels dans le stock et \u00e0 les pr\u00e9parer pour former des colis pr\u00eats \u00e0 \u00eatre exp\u00e9di\u00e9s aux clients.<\/strong> Il s'agit d'une op\u00e9ration fondamentale dans toute entreprise de traitement des commandes : la succession d'\u00e9tapes qui transforme la commande d'un client en un colis pr\u00eat \u00e0 \u00eatre exp\u00e9di\u00e9. Ce processus comprend quatre \u00e9tapes : la r\u00e9ception des commandes, la pr\u00e9paration des articles en rayon, leur emballage selon les normes en vigueur et leur remise \u00e0 un transporteur. Dans ce guide, nous explorons le fonctionnement concret de la pr\u00e9paration et de l'emballage des commandes, les diff\u00e9rentes m\u00e9thodes utilis\u00e9es par les entrep\u00f4ts, les d\u00e9fis courants auxquels ils sont confront\u00e9s, ainsi que la mani\u00e8re dont les logiciels de gestion d'entrep\u00f4t optimisent l'ensemble de l'op\u00e9ration.<\/p>\n<p>Remarque : certaines recherches portant sur les termes \u201c pick and pack \u201d renvoient des r\u00e9sultats concernant des services externalis\u00e9s de pr\u00e9paration et d\u2019emballage, c\u2019est-\u00e0-dire des centres de traitement des commandes qui prennent en charge l\u2019ensemble du processus \u00e0 votre place. Il s\u2019agit d\u2019une option valable pour certaines entreprises, mais ce guide vise avant tout \u00e0 vous aider \u00e0 comprendre le processus de pr\u00e9paration et d\u2019emballage en lui-m\u00eame, ainsi que les logiciels et les pratiques op\u00e9rationnelles qui permettent de le mettre en \u0153uvre \u00e0 grande \u00e9chelle.<\/p>\n<h2>Qu'est-ce que le \u00ab pick and pack \u00bb ?<\/h2>\n<p>Le \u00ab pick and pack \u00bb d\u00e9signe l'op\u00e9ration logistique consistant \u00e0 pr\u00e9lever des unit\u00e9s de stock individuelles dans des emplacements de stockage et \u00e0 les emballer afin d'honorer les commandes des clients. Il est au c\u0153ur des activit\u00e9s du commerce \u00e9lectronique, de la logistique 3PL et de la distribution. Ce processus consiste \u00e0 acheminer un produit du rayonnage jusqu'\u00e0 l'exp\u00e9dition ; il s'agit d'une succession de petites d\u00e9cisions et d'actions qui, lorsqu'elles sont bien ex\u00e9cut\u00e9es, permettent de livrer les commandes rapidement et avec pr\u00e9cision ; lorsqu'elles sont mal ex\u00e9cut\u00e9es, elles entra\u00eenent des co\u00fbts li\u00e9s aux erreurs, aux retours et \u00e0 l'inefficacit\u00e9 de la main-d'\u0153uvre.<\/p>\n<p>Dans sa forme la plus simple, le processus de pr\u00e9paration des commandes se d\u00e9roule en quatre \u00e9tapes :<\/p>\n<ul>\n<li><strong>Accus\u00e9 de r\u00e9ception de la commande :<\/strong> Les commandes des clients sont transmises au syst\u00e8me de l'entrep\u00f4t (via une plateforme de commerce \u00e9lectronique, EDI, API ou par e-mail). Le syst\u00e8me affecte les donn\u00e9es de la commande \u00e0 une liste de pr\u00e9paration ou \u00e0 une t\u00e2che.<\/li>\n<li><strong>S\u00e9lection :<\/strong> Le personnel de l'entrep\u00f4t ou les syst\u00e8mes d'automatisation r\u00e9cup\u00e8rent les articles appropri\u00e9s \u00e0 leurs emplacements de stockage, en suivant les consignes des listes de pr\u00e9l\u00e8vement ou des instructions fournies par les scanners portables.<\/li>\n<li><strong>Emballage :<\/strong> Les articles sont regroup\u00e9s dans un poste d'emballage, plac\u00e9s dans des emballages contenant les mat\u00e9riaux appropri\u00e9s (mat\u00e9riaux de rembourrage, isolants, etc.) et \u00e9tiquet\u00e9s \u00e0 l'attention du transporteur.<\/li>\n<li><strong>Livraison :<\/strong> Le colis est remis \u00e0 un partenaire de livraison (DPD, Evri, Royal Mail, UPS, etc.) pour la livraison au client (dernier tron\u00e7on).<\/li>\n<\/ul>\n<p>La rapidit\u00e9, la pr\u00e9cision et le co\u00fbt de ce processus ont une incidence directe sur la satisfaction client, la rentabilit\u00e9 et l'avantage concurrentiel. Un entrep\u00f4t qui traite et emballe 1 000 commandes par jour avec une pr\u00e9cision de 99% et un minimum de retouches est fondamentalement diff\u00e9rent d'un entrep\u00f4t qui atteint une pr\u00e9cision de 97% et passe des heures \u00e0 r\u00e9gulariser les anomalies.<\/p>\n<h2>Pourquoi la pr\u00e9paration des commandes et l'emballage sont-ils importants ?<\/h2>\n<p>La pr\u00e9paration des commandes est essentielle, car elle fait le lien entre les stocks et la livraison au client. Voici pourquoi elle m\u00e9rite une attention particuli\u00e8re sur le plan op\u00e9rationnel :<\/p>\n<p><strong>Exp\u00e9rience client.<\/strong> La pr\u00e9cision et la rapidit\u00e9 des commandes d\u00e9terminent les attentes des clients. Un article erron\u00e9 ou une livraison avec une semaine de retard entra\u00eene des remboursements, des retours, des avis n\u00e9gatifs et la perte de clients fid\u00e8les. Les commer\u00e7ants pr\u00e9sents sur Amazon en sont parfaitement conscients : les exp\u00e9ditions tardives ou erron\u00e9es entra\u00eenent des avertissements ou la suppression du compte de la plateforme.<\/p>\n<p><strong>Co\u00fbt par commande.<\/strong> La main-d\u2019\u0153uvre d\u00e9di\u00e9e \u00e0 la pr\u00e9paration et \u00e0 l\u2019emballage des commandes repr\u00e9sente souvent le poste de co\u00fbt contr\u00f4lable le plus important dans une op\u00e9ration de logistique. Au Royaume-Uni, un prestataire logistique tiers (3PL) d\u00e9pense g\u00e9n\u00e9ralement entre 2,50 \u00a3 et 5,00 \u00a3 par commande pr\u00e9par\u00e9e et emball\u00e9e pour ses clients de petite et moyenne taille. Si l'on extrapole ce chiffre \u00e0 10 000 commandes par jour, cela repr\u00e9sente des centaines de milliers de livres sterling de co\u00fbts de main-d'\u0153uvre mensuels. Une am\u00e9lioration de l'efficacit\u00e9 de la pr\u00e9paration des commandes (10%), une r\u00e9duction du nombre d'\u00e9tapes, un acheminement plus intelligent et un meilleur guidage par le syst\u00e8me se r\u00e9percutent directement sur le r\u00e9sultat net.<\/p>\n<p><strong>Pr\u00e9cision et rendements.<\/strong> Chaque article mal s\u00e9lectionn\u00e9 se traduit par une r\u00e9clamation client, un retour et des frais de r\u00e9approvisionnement. La gestion des retours co\u00fbte cher : le produit doit \u00eatre r\u00e9ceptionn\u00e9, inspect\u00e9, remis en stock et le client rembours\u00e9. De nombreuses entreprises de commerce \u00e9lectronique perdent entre 5 et 10% de chiffre d\u2019affaires \u00e0 cause de retours qui auraient pu \u00eatre \u00e9vit\u00e9s. La v\u00e9rification par scan au moment de la pr\u00e9paration des commandes, qui permet de s'assurer que le code-barres correspond bien \u00e0 la commande, r\u00e9duit les erreurs de pr\u00e9paration \u00e0 presque z\u00e9ro. JODA Freight, un prestataire logistique tiers (3PL) britannique, a vu la pr\u00e9cision de ses stocks passer d'un peu plus de 90 % \u00e0 99,8% apr\u00e8s avoir mis en place un syst\u00e8me de gestion d'entrep\u00f4t (WMS) dot\u00e9 d'une v\u00e9rification par scan en temps r\u00e9el.<\/p>\n<p><strong>Travail et mise \u00e0 l'\u00e9chelle.<\/strong> Les entrep\u00f4ts dont le volume de commandes ne cesse d'augmenter se heurtent \u00e0 leurs limites avec des processus manuels. Les listes de pr\u00e9paration sur papier deviennent difficiles \u00e0 distribuer, les employ\u00e9s mettent en place leurs propres raccourcis, et les p\u00e9riodes de pointe g\u00e9n\u00e8rent le chaos en l'absence d'un syst\u00e8me permettant d'organiser les flux. Un syst\u00e8me de gestion d'entrep\u00f4t (WMS) sp\u00e9cialement con\u00e7u \u00e9limine ces limites : il organise la pr\u00e9paration des commandes de mani\u00e8re \u00e0 minimiser les distances \u00e0 parcourir, regroupe les commandes de mani\u00e8re intelligente et adapte les effectifs sans difficult\u00e9 de formation.<\/p>\n<h2>Le processus de pr\u00e9paration des commandes : de la r\u00e9ception de la commande \u00e0 l'exp\u00e9dition<\/h2>\n<p>Il est essentiel de bien comprendre l'ensemble du flux avant de pouvoir l'optimiser. Voici comment une commande type est trait\u00e9e dans un entrep\u00f4t :<\/p>\n<h3>1. R\u00e9ception et traitement des commandes<\/h3>\n<p>Une commande arrive dans le syst\u00e8me de l'entrep\u00f4t, qu'elle provienne d'une boutique Shopify, d'un flux EDI d'un partenaire de distribution, d'un TMS (syst\u00e8me de gestion des transports) ou d'une saisie manuelle. Le syst\u00e8me doit v\u00e9rifier que le stock est disponible (ou allouer le stock s'il s'agit d'un syst\u00e8me multi-entrep\u00f4ts), convertir la commande en instruction de pr\u00e9paration et l'affecter \u00e0 un lot ou \u00e0 une vague de pr\u00e9paration.<\/p>\n<p>Dans les entrep\u00f4ts g\u00e9r\u00e9s manuellement, cette \u00e9tape constitue le premier goulot d'\u00e9tranglement : les commandes s'accumulent dans une bo\u00eete de r\u00e9ception, quelqu'un les saisit dans un tableur, et plusieurs heures s'\u00e9coulent avant que la pr\u00e9paration des commandes ne commence. Dans les entrep\u00f4ts g\u00e9r\u00e9s par logiciel, les commandes sont imm\u00e9diatement achemin\u00e9es vers une file d'attente de pr\u00e9paration, tri\u00e9es par emplacement, regroup\u00e9es par lots pour plus d'efficacit\u00e9, et pr\u00eates \u00e0 \u00eatre trait\u00e9es par le personnel en quelques minutes.<\/p>\n<h3>2. Pr\u00e9paration des commandes : localisation et s\u00e9lection des articles<\/h3>\n<p>Le r\u00f4le du pr\u00e9parateur de commandes consiste \u00e0 localiser les articles appropri\u00e9s dans l'entrep\u00f4t et \u00e0 les acheminer vers la zone d'emballage. La m\u00e9thode varie selon les op\u00e9rations ; consultez la section \u201c Explication des m\u00e9thodes de pr\u00e9paration des commandes \u201d ci-dessous pour obtenir des informations d\u00e9taill\u00e9es. Mais le d\u00e9fi commun reste le m\u00eame : r\u00e9duire au maximum le temps de pr\u00e9paration tout en garantissant la pr\u00e9cision.<\/p>\n<p>Une liste de pr\u00e9l\u00e8vement sur papier est source de friction : le pr\u00e9parateur doit la lire, s\u2019orienter de m\u00e9moire ou \u00e0 l\u2019aide de la signal\u00e9tique, trouver le rayonnage, localiser l\u2019article au sein de ce rayonnage (ce qui peut pr\u00eater \u00e0 confusion si les articles sont empil\u00e9s), s\u00e9lectionner la bonne quantit\u00e9 et la cocher. Les erreurs se multiplient aux heures de pointe, lorsque la charge cognitive est \u00e9lev\u00e9e et que le personnel est fatigu\u00e9. Un syst\u00e8me bas\u00e9 sur les codes-barres \u00e9limine ces frictions : le pr\u00e9parateur scanne son identifiant ou une t\u00e2che, le syst\u00e8me le guide vers chaque emplacement \u00e0 l\u2019aide d\u2019un num\u00e9ro affich\u00e9 sur un terminal portable, il scanne le code-barres de l\u2019emplacement, puis celui de l\u2019article. Si les codes-barres ne correspondent pas, le syst\u00e8me l\u2019arr\u00eate imm\u00e9diatement, \u00e9vitant ainsi toute erreur cach\u00e9e qui ne serait d\u00e9tect\u00e9e qu\u2019au moment de l\u2019emballage. C\u2019est ce qu\u2019on appelle la v\u00e9rification \u201c scan-to-location \u201d (scanner l\u2019emplacement) ou \u201c scan-to-item \u201d (scanner l\u2019article), et c\u2019est le moyen le plus efficace pour atteindre une pr\u00e9cision de pr\u00e9l\u00e8vement de 99,1 % TP3T+.<\/p>\n<h3>3. Emballage et contr\u00f4le qualit\u00e9<\/h3>\n<p>Les articles arrivent au poste d'emballage, soit individuellement (dans le cadre du pr\u00e9l\u00e8vement \u00e0 l'unit\u00e9), soit par lots (dans le cadre du pr\u00e9l\u00e8vement par lots ou par vagues). Le r\u00f4le de l'emballeur consiste \u00e0 :<\/p>\n<ul>\n<li>V\u00e9rifiez que les articles correspondent \u00e0 la commande (deuxi\u00e8me v\u00e9rification ; la premi\u00e8re a eu lieu lors de la pr\u00e9paration de la commande)<\/li>\n<li>Choisissez des emballages et des mat\u00e9riaux de calage adapt\u00e9s (mat\u00e9riaux de rembourrage, papier bulle, papier de soie, sachets de remplissage) afin d'\u00e9viter tout dommage aux produits.<\/li>\n<li>Apposez une \u00e9tiquette d'exp\u00e9dition comportant l'adresse correcte et un code-barres<\/li>\n<li>Pesez le colis (de nombreux transporteurs facturent au poids ; la balance permet de d\u00e9tecter les erreurs d'emballage, comme les articles manquants)<\/li>\n<li>D\u00e9posez le colis dans un point de collecte de colis ou \u00e0 un quai de regroupement<\/li>\n<\/ul>\n<p>Dans les op\u00e9rations \u00e0 cadence \u00e9lev\u00e9e, les emballeurs travaillent \u00e0 partir d\u2019\u00e9tiquettes de pr\u00e9paration scannables ou de cartons g\u00e9n\u00e9r\u00e9s par le syst\u00e8me ; chaque colis est associ\u00e9 \u00e0 la commande dans le syst\u00e8me de l\u2019entrep\u00f4t. Si un article manque dans un carton, celui-ci doit \u00eatre renvoy\u00e9 au service de pr\u00e9paration des commandes pour \u00eatre corrig\u00e9 avant d\u2019\u00eatre exp\u00e9di\u00e9. Ce circuit de r\u00e9troaction en temps r\u00e9el permet d\u2019\u00e9viter les erreurs \u201c silencieuses \u201d qui, sans cela, ne seraient d\u00e9couvertes qu\u2019une fois le colis livr\u00e9 chez le client.<\/p>\n<h3>4. Exp\u00e9dition et remise<\/h3>\n<p>Le colis est remis au transporteur (ou mis en attente dans une zone de regroupement en vue d\u2019un enl\u00e8vement group\u00e9). Le syst\u00e8me d\u2019entrep\u00f4t s\u2019int\u00e8gre \u00e0 l\u2019API du transporteur pour imprimer l\u2019\u00e9tiquette au format appropri\u00e9, enregistrer les donn\u00e9es de suivi et mettre \u00e0 jour l\u2019avis d\u2019exp\u00e9dition du client. De nombreux transporteurs britanniques utilisent d\u00e9sormais des syst\u00e8mes avanc\u00e9s de routage et de suivi ; DPD, Evri et DHL proposent tous des int\u00e9grations API pour une visibilit\u00e9 en temps r\u00e9el. Un bon syst\u00e8me de gestion d\u2019entrep\u00f4t (WMS) enregistre la r\u00e9f\u00e9rence de suivi du transporteur et la transmet au client ainsi qu\u2019aux syst\u00e8mes de reporting internes \u00e0 des fins d\u2019analyse des performances.<\/p>\n<h2>Explication des m\u00e9thodes de pr\u00e9l\u00e8vement<\/h2>\n<p>La pr\u00e9paration et l'emballage des commandes peuvent sembler simples, mais la m\u00e9thode choisie a un impact consid\u00e9rable sur les co\u00fbts et la rapidit\u00e9. Chaque type de commande, chaque volume et chaque produit n\u00e9cessite une strat\u00e9gie diff\u00e9rente. Voici les quatre principales m\u00e9thodes :<\/p>\n<table>\n<thead>\n<tr>\n<th>M\u00e9thode<\/th>\n<th>Comment \u00e7a marche ?<\/th>\n<th>Id\u00e9al pour<\/th>\n<th>\u00c0 quelques pas<\/th>\n<th>D\u00e9bit<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Piece picking<\/strong> (single-order picking)<\/td>\n<td>The picker collects all items for one order before moving to the next. One trip per order through the warehouse.<\/td>\n<td>Low-volume, high-SKU operations; made-to-order; specialist products<\/td>\n<td>High (one order often spans all warehouse zones)<\/td>\n<td>Low (50 to 100 orders\/shift per picker)<\/td>\n<\/tr>\n<tr>\n<td><strong>Pr\u00e9paration de commande par lots<\/strong> (multi-order picking)<\/td>\n<td>The picker collects items for multiple orders in a single route, grouping orders by shared item locations. Items are sorted to their orders at packing.<\/td>\n<td>High-volume, repeated SKUs; ecommerce fulfilment<\/td>\n<td>Low (one route per batch of orders, not per order)<\/td>\n<td>High (200 to 400 orders\/shift per picker)<\/td>\n<\/tr>\n<tr>\n<td><strong>Zone de pr\u00e9l\u00e8vement<\/strong> (area responsibility)<\/td>\n<td>The warehouse is divided into zones (e.g. chilled, ambient, hazmat). Each picker owns a zone and picks items for all orders passing through that zone in a wave.<\/td>\n<td>Multi-zone operations (food\/beverage, temperature control); large SKU counts<\/td>\n<td>Very low (picker never leaves their zone)<\/td>\n<td>Very high (can pick 500+ order lines\/shift in a zone)<\/td>\n<\/tr>\n<tr>\n<td><strong>Picking en vagues<\/strong> (cluster picking)<\/td>\n<td>Orders are released in waves, and multiple pickers (or zones) work in parallel on the same batch of orders. Combines batch and zone logic.<\/td>\n<td>Large operations with multiple zones and high order volume<\/td>\n<td>Low (optimised routes per zone and picker)<\/td>\n<td>Very high (leverages parallelism and route optimisation)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Most modern ecommerce and 3PL operations use batch, zone, or wave picking because they minimise walking distance and maximise staff throughput. Piece picking is reserved for niche, low-volume scenarios where order variety is too high to batch effectively.<\/p>\n<h3>What is batch picking?<\/h3>\n<p>Batch picking deserves a closer look because it&#8217;s the workhorse of high-volume ecommerce. In batch picking, the system groups multiple customer orders (e.g. 10 to 20 orders) that share common item locations. A single picker collects all items for the batch in one route, guided by an optimised pick list that minimises walking. The items are then returned to a packing station, where they are sorted and consolidated back into individual customer orders.<\/p>\n<p>The efficiency gain is dramatic: instead of the picker walking the entire warehouse 10 times (once per order), they walk it once, collecting items for all 10 orders in a single pass. Clarus&#8217;s Smart Wave Picking sequences pick routes automatically, claiming a 50% reduction in travel time compared to manual pick-list routing.<\/p>\n<p>The tradeoff is complexity at the packing station, packers must be disciplined about sorting items into the correct orders. If the batch system doesn&#8217;t track which items belong to which order, errors multiply at packing. This is why modern batch picking always runs on a WMS: the system tracks every item&#8217;s destination order, guides the picker with barcodes, and enforces sort discipline at packing.<\/p>\n<h2>Packing methods and best practice<\/h2>\n<p>Packing is less glamorous than picking, but it&#8217;s where customer experience is actually delivered. A damaged product, a late arrival because the parcel was packed too heavy, or missing insulation in cold weather, these are packing failures.<\/p>\n<h3>Standard packaging and void-fill<\/h3>\n<p>Standard packing follows a simple principle: the package must protect the product through the shipping journey. This means:<\/p>\n<ul>\n<li><strong>Box selection:<\/strong> The box must be snug around the product, too small and the parcel is crushed, too large and contents shift during transit. Many warehouses maintain a size matrix (small, medium, large) and train packers to choose by product dimensions.<\/li>\n<li><strong>Void fill:<\/strong> Void-fill material (bubble wrap, kraft paper, air pillows, void bags) fills empty space in the box so products can&#8217;t move. Best practice is to completely eliminate voids, every gap filled. Underestimating void fill costs more in returns than it saves in materials.<\/li>\n<li><strong>Fragile items:<\/strong> Breakables (glasses, electronics) should be double-boxed or wrapped in additional layers. Internal boxes should have padding between them.<\/li>\n<li><strong>Temperature-sensitive items:<\/strong> Chilled and frozen products need insulation and often cold packs (gel packs, dry ice, thermal liners). Shipping a frozen item in an uninsulated box guarantees a refund and a bad review.<\/li>\n<\/ul>\n<h3>Custom packaging and brand experience<\/h3>\n<p>Growing ecommerce brands use custom packaging to stand out. Branded boxes, thank-you notes, tissue paper, and bespoke inserts create unboxing moments that drive social sharing and repeat purchases. Operationally, this adds complexity: packers must be trained to include every element, brands must stock multiple packaging types, and the WMS must route orders to the correct packing lane based on brand or order attributes.<\/p>\n<h3>Packing best practice<\/h3>\n<p>High-performing warehouses embed these practices:<\/p>\n<ul>\n<li><strong>Packing station ergonomics:<\/strong> Stations should be set up at elbow height, with common materials within arm&#8217;s reach. Packers should stand, not sit, it improves speed and reduces strain injury.<\/li>\n<li><strong>Quality spot-checks:<\/strong> Supervisors should randomly select and open packed parcels to verify contents match the order and packing standard is met. Catching packing errors before shipment is far cheaper than managing returns.<\/li>\n<li><strong>Weight verification:<\/strong> Scales should be integrated into the packing station. A significant weight variance between actual and expected often signals a missing item or a pick error caught too late.<\/li>\n<li><strong>Parcel labelling:<\/strong> Labels must be applied to a flat surface (not a corner or seam), in a location where courier scanners can read them reliably. Handwritten labels are error-prone; system-generated thermal labels are standard.<\/li>\n<li><strong>Carrier optimisation:<\/strong> Different items and destinations favour different carriers. A small parcel to London might go via Royal Mail; a heavy item to Glasgow might go via DHL. The WMS should integrate with carrier rate engines to select the cheapest, fastest option per parcel.<\/li>\n<\/ul>\n<h2>Key challenges in pick and pack<\/h2>\n<p>Understanding the common failure modes helps you prioritise improvements. Here are the problems warehouses actually face:<\/p>\n<h3>Pick accuracy and error measurement<\/h3>\n<p>Pick errors are invisible until they reach the customer. Many warehouses track overall return rates but can&#8217;t pinpoint whether errors came from picking, packing, or other causes. Best practice is to measure pick accuracy directly: implement scan verification (barcode match at pick time), calculate the percentage of picks verified without exception, and track the exception rate. A 99% pick accuracy rate means 1 error per 100 picks; a 99.9% rate means 1 error per 1,000 picks. The difference between 99% and 99.9% is often the difference between a 3% return rate and a 0.3% return rate, a tenfold improvement.<\/p>\n<h3>Cost per pick and labour pressure<\/h3>\n<p>Manual picking at scale creates a cost ceiling. A picker can physically select perhaps 30 to 50 items per hour in a complex warehouse, or 150+ items per hour in a simple, well-racked one. At \u00a310 to \u00a315 per hour (standard UK warehouse wage), the cost per pick is \u00a30.20 to \u00a30.50 before overhead. When you&#8217;re competing on margins, every penny counts. Automation (conveyors, automated storage systems, picking robots) reduces this, but capital cost is high. Most mid-market operations improve cost per pick through method (batch vs piece), system guidance (WMS pick-path optimisation), and process (standardised layouts, pre-staging, zone picking).<\/p>\n<h3>Inventory inaccuracy and cycle counting<\/h3>\n<p>If the WMS says a location holds 50 units but there are 48, the picking system will eventually try to pick from an empty location. The picker either wastes time searching, or the pick fails and the order must be delayed. Inventory drift accumulates, perhaps 2 to 3% per year in a manual warehouse, until stocktakes become painful. A good WMS enforces cycle-counting discipline: staff count a subset of high-movement locations daily, rather than a company-wide stocktake once per year. Clarus integrates with barcode scanning to make cycle-counting fast; JODA Freight reduced their annual stocktake from weeks to days.<\/p>\n<h3>Labour turnover and training friction<\/h3>\n<p>Warehouse staff often have high turnover. New staff need to learn where items are stored, how to use the picking system, and the packing standard. Without clear system guidance, this takes weeks. A well-designed WMS (good handheld interfaces, clear visual directions, simple workflows) reduces training time significantly. A new picker can be productive within days with a WMS; without one, it&#8217;s weeks.<\/p>\n<h3>Multi-client complexity (3PLs)<\/h3>\n<p>3PLs manage stock for many clients, often in the same physical warehouse. Client A&#8217;s picking requirements, billing rules, and SLAs differ from Client B&#8217;s. A generic WMS treats all clients the same, creating friction: client-specific rules must be coded, or packing staff must remember dozens of exceptions. A purpose-built 3PL WMS isolates each client&#8217;s inventory, enforces client-specific picking methods, and tracks billing events separately. This eliminates manual client-switching overhead and makes scaling new clients fast.<\/p>\n<h3>Returns management<\/h3>\n<p>Reverse logistics, the process of accepting returned items, has become as important as forward picking. Returned items must be inspected, restocked (if saleable), or scrapped. Without a clear process, returns pile up, inventory gets confused, and refunds are delayed. A WMS should have a returns workflow that guides staff through inspection, categorises returns (saleable, damaged, defective, customer changed mind), and routes items back to stock or to a disposal queue. Mapping out returns as a reverse pick-and-pack operation often reveals quick wins.<\/p>\n<h2>Software solutions for pick and pack<\/h2>\n<p>Manual operations hit their limit around 100 to 200 orders per day. Beyond that, software becomes essential. Here&#8217;s what software should do:<\/p>\n<h3>Warehouse management system (WMS)<\/h3>\n<p>A WMS is the operational backbone of pick and pack. It should:<\/p>\n<ul>\n<li>Receive orders from multiple sources (Shopify, Amazon, EDI, API, email)<\/li>\n<li>Allocate stock and create picking tasks or waves automatically<\/li>\n<li>Guide picking via barcode scan verification (mobile device or handheld scanner)<\/li>\n<li>Optimise pick routes to minimise walking distance (wave picking, zone picking)<\/li>\n<li>Track inventory in real-time and update stock on hand as picks are confirmed<\/li>\n<li>Segregate stock by client (in 3PL operations) with per-client billing and reporting<\/li>\n<li>Enforce packing standards and capture weight, dimensions, and carrier selection<\/li>\n<li>Integrate with shipping carriers for label generation and tracking updates<\/li>\n<li>Provide client-facing portals (in 3PL and distribution) so customers can see real-time stock and order status<\/li>\n<li>Audit trail, every stock movement, every pick exception, every billing event is logged<\/li>\n<\/ul>\n<p>Clarus WMS, a cloud-native system designed for 3PLs and distributors, is an example of purpose-built software. It handles multi-client stock segregation, automated billing (capturing every picking, packing, and handling event), and client self-service portals, features that generic WMS platforms bolt on at high cost or leave to custom coding.<\/p>\n<h3>Barcode scanning and RFID<\/h3>\n<p>Barcode scanning is the most practical verification method for pick and pack. A barcode on every location and every item means staff can scan, confirm, and move on, no ambiguity. RFID (radio-frequency identification) is more advanced: tags on items and locations can be read from distance, enabling automated picking (items moved on conveyors) and inventory monitoring without manual scans. RFID is expensive and useful only at large scale, so most UK operations use standard barcode scanning (EAN-13 or Code 128).<\/p>\n<h3>Mobile picking devices and handheld scanners<\/h3>\n<p>Staff need guidance as they move through the warehouse. Mobile picking devices (Android phones or purpose-built handheld scanners, e.g. Zebra TC25 or Honeywell CK65) display the next location, verify scans, and mark tasks complete in real-time. The device must be rugged (dust, water, impact), have good battery life, and integrate seamlessly with the WMS. A good WMS system should allow customisable picking workflows on the handheld, e.g. &#8220;scan task ID, scan location, scan item, confirm quantity&#8221;, tailored to your operation.<\/p>\n<h3>Automation and robotics<\/h3>\n<p>Automated picking (robots that select items from shelves or goods-to-person systems that bring shelves to pickers) is the frontier of pick and pack. Automated systems claim 400 to 600 picks per hour per station, compared to 150 to 300 for manual picking. But capital cost is \u00a3500,000 to \u00a32,000,000+ for a system, so ROI only works at large scale (1,000+ orders\/day with stable SKU mix). Most mid-market operations stick with manual picking optimised by WMS routing.<\/p>\n<h2>Best practice tips for efficiency<\/h2>\n<p>Small improvements compound. Here are the highest-impact changes:<\/p>\n<h3>Warehouse layout optimisation<\/h3>\n<p>Layout has huge impact on walking distance. Principles:<\/p>\n<ul>\n<li><strong>Frequency-based placement:<\/strong> High-movement items should be closest to the packing area. Slow-moving items go further back. This reduces average walking distance per pick.<\/li>\n<li><strong>Aisle design:<\/strong> Straight, wide aisles are faster than narrow winding ones. One-way traffic flows are clearer than two-way.<\/li>\n<li><strong>Vertical storage:<\/strong> Use height. A 3-high racking system (items at ankle, waist, shoulder height) covers more SKUs in less floor space and reduces walking, pickers spend less time searching at hard-to-reach heights if slow-moving items are there.<\/li>\n<li><strong>Batch staging:<\/strong> Before a batch is released to picking, stage common items in a pre-pick area so the picker&#8217;s first stop is shorter.<\/li>\n<\/ul>\n<h3>Inventory management and FIFO\/FEFO rotation<\/h3>\n<p>Expired or spoiled items cost money and create customer complaints. Rotation rules (FIFO, first in, first out, or FEFO, first expire, first out) must be enforced by the system, not by memory. A WMS with expiry date or best-before capture can automatically allocate the oldest stock first at picking, or flag approaching expiry dates for clearance.<\/p>\n<h3>Process improvements and continuous optimisation<\/h3>\n<p>Track and analyse pick metrics: picks per hour, error rate, exceptions per shift, downtime. Identify bottlenecks (e.g. picking time is up 15%, packing time is stable). Meet with staff, they see problems first. Small changes (relocated slow-moving items, new shelf labelling, adjusted shift breaks) often drive 10 to 15% efficiency gains.<\/p>\n<h3>Technology adoption (barcode, scanning, WMS)<\/h3>\n<p>Investing in even simple technology (barcode labels, basic handheld scanner, light-duty WMS) often pays back in 6 to 12 months through reduced errors and faster throughput. Don&#8217;t wait for a full automation overhaul, incremental adoption works.<\/p>\n<h3>Staff training and engagement<\/h3>\n<p>Warehouse staff are the execution. Invest in induction (teach the picking method and system), ongoing training (introduce new products, processes, or equipment), and feedback (tell staff their pick accuracy rate monthly, celebrate improvements). Engaged staff pick faster and with fewer errors.<\/p>\n<h2>How does the pick and pack process work? A practical example<\/h2>\n<p>Let&#8217;s walk through a real order from arrival to dispatch. A customer orders two items (a t-shirt and a hoodie) from an ecommerce store integrated with the WMS via API.<\/p>\n<p><strong>Order receipt (11:00am):<\/strong> The order lands in the WMS and is immediately matched against live inventory. Both items are in stock at warehouse location A1-02 (t-shirt) and B3-15 (hoodie). The system batches this order with 14 others received in the past 10 minutes, creating a batch of 15 orders. Priority is set by customer (standard or express shipping) and location (orders for geographically similar deliveries are batched together).<\/p>\n<p><strong>Picking (11:15am):<\/strong> A picker receives a batch task on their handheld device. The system displays location A1-02 first (t-shirt, qty 1). The picker walks to A1-02, scans the location barcode (location verified), scans the item barcode (item verified), and confirms qty 1. The device moves on to the next location. This continues until all 15 orders&#8217; items are collected. Crucially: if the picker scans the wrong barcode at any step, the device rejects it and alerts the supervisor. Errors are caught in real time, not at the customer&#8217;s door.<\/p>\n<p><strong>Consolidation and packing (11:45am):<\/strong> The 15 orders&#8217; items are returned to the packing station. A packing conveyor or cart delivers them sorted by order (the WMS sorts them after picking). The packer pulls order 1, verifies the two items match the order (second check), selects a medium box (fitted to the product size), adds void-fill, applies a thermal label printed by the WMS with the correct carrier, and places the parcel into a dispatch bin.<\/p>\n<p><strong>Shipping (12:30pm):<\/strong> The dispatch bin is scanned and handed to the carrier pickup point. The WMS sends a tracking update to the customer (&#8220;Your order is on its way, tracking number XYZ&#8221;). The order is now complete.<\/p>\n<p>This entire process, from order to dispatch, takes 1.5 hours. Without a WMS, the order would sit in an inbox for an hour while staff manually created picking and packing lists, introducing delay and error risk.<\/p>\n<h2>Discutez avec un expert en entreposage<\/h2>\n<p>Si vous \u00eates en train d'\u00e9valuer vos options et que vous souhaitez d\u00e9couvrir comment fonctionne concr\u00e8tement un progiciel de gestion d'entrep\u00f4t (WMS) sp\u00e9cialement con\u00e7u \u00e0 cet effet, n'h\u00e9sitez pas \u00e0 contacter Clarus. Nous collaborons avec des prestataires logistiques tiers (3PL) et des distributeurs \u00e0 travers tout le Royaume-Uni pour mettre en place un progiciel de gestion d'entrep\u00f4t qui s'adapte \u00e0 votre mode de fonctionnement, et non l'inverse.<\/p>\n<p><a href=\"https:\/\/stg-khh4l5.elementor.cloud\/fr\/entrer-en-contact\/\">Contactez notre \u00e9quipe<\/a> pour discuter de vos besoins.<\/p>","protected":false},"excerpt":{"rendered":"<p>Qu'est-ce que le \u00ab pick and pack \u00bb ? Comment fonctionne le processus d'entrep\u00f4t, quelles sont les m\u00e9thodes de pr\u00e9paration des commandes, quelles sont les bonnes pratiques en mati\u00e8re d'emballage et comment un logiciel WMS g\u00e8re-t-il tout cela ?.<\/p>","protected":false},"author":207386994,"featured_media":0,"comment_status":"closed","ping_status":"","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_angie_page":false,"inline_featured_image":false,"page_builder":"","footnotes":""},"categories":[1578],"tags":[1679],"class_list":["post-33630","post","type-post","status-publish","format-standard","hentry","category-articles","tag-article-new"],"acf":{"faq_new":"<h4>What are pick and pack services?<\/h4>\n\n<p>Pick and pack services are outsourced fulfilment offered by third-party logistics (3PL) providers. Instead of managing your own warehouse, you store inventory with the 3PL, and they handle order picking, packing, and shipping on your behalf. Services typically cost \u00a32.50 to \u00a35.00 per order for standard pick-and-pack fulfilment, plus storage fees (\u00a37 to \u00a315 per pallet per month). The advantage is you avoid warehouse overhead and infrastructure; the tradeoff is less control and recurring costs. For ecommerce brands sending 100+ orders per day, outsourcing can be cheaper and faster than building an in-house operation.<\/p>\n\n<h4>What is a pick and pack warehouse?<\/h4>\n\n<p>A pick and pack warehouse is a facility designed to receive, store, and fulfil customer orders. It's organised for speed and accuracy: aisles are clear for picking, packing stations are ergonomic, and the layout minimises walking distance. Technology matters, a modern pick and pack warehouse uses barcodes, handheld scanners, and a WMS to guide staff and verify every pick and pack step. Without technology, it's just a storage unit with organised shelves. With technology, it becomes a coordinated system that can reliably fulfil thousands of orders per day with 99%+ accuracy.<\/p>\n\n<h4>What is pick, pack and ship?<\/h4>\n\n<p>Pick, pack and ship (or \"pick, pack, and post\") is the complete order fulfilment workflow: picking items from inventory, packing them with appropriate materials, and arranging shipment via a carrier to the customer. Some 3PLs and fulfilment providers use \"pick, pack and ship\" as a shorthand for their full-service offering, implying that storage, picking, packing, and shipping are all included. It's the same process described in this guide, just packaged as a service.<\/p>\n\n<h4>How do I reduce pick and pack costs?<\/h4>\n\n<p>The main cost driver is labour. To reduce cost per pick, focus on: (1) picking method, batch or wave picking is cheaper than piece picking; (2) system guidance, a WMS with optimised pick routes cuts walking distance by 30 to 50%; (3) layout, frequent items near packing, slow items at the back; (4) volume, once you're above 500+ orders per day, the fixed cost of a WMS is justified. Automation (conveyors, picking robots) works at very high volume (2,000+ orders\/day) but requires capital investment. For most operations, incremental improvements (better layout, WMS, batch picking) deliver the best ROI.<\/p>\n\n<h4>What is the difference between batch picking and wave picking?<\/h4>\n\n<p>Batch picking groups multiple orders that share item locations and picks them in one route; the packer then sorts items into individual customer orders at the packing station. Wave picking combines batch and zone logic: orders are released in waves, and multiple pickers (or warehouse zones) work in parallel, each optimising their own route. Wave picking is more complex to orchestrate but delivers higher throughput because multiple staff are picking in parallel, each following an optimised path. Batch picking is simpler to manage but single-threaded (one picker per batch). For 1,000+ orders\/day, wave picking is standard.<\/p>"},"aioseo_notices":[],"aioseo_head":"\n\t\t<!-- All in One SEO Pro 5.0.0.1 - aioseo.com -->\n\t<meta name=\"description\" content=\"What is pick and pack? 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