Order Preparation: A Real Challenge for Warehouses

Why is order preparation a strategic challenge for warehouses?

In today’s modern logistics landscape, order preparation in warehouses is often the main bottleneck. While the rest of the supply chain runs smoothly, it’s at this stage that delays, errors, and extra costs tend to pile up.

According to a study by Logistics Management, up to 60% of a warehouse’s operating costs are tied to order picking. That figure alone speaks volumes about the critical nature of this process.

The main causes of order preparation issues

Poorly optimized warehouse layout

A disorganized warehouse setup—with no clear zoning (hot/cold zones) or efficient picking paths—leads to unnecessary travel for operators. The time wasted locating products translates directly into lost productivity.

Outdated manual processes

Many warehouses, especially in SMEs, still rely on paper-based or semi-digital methods (spreadsheets, printed order slips). The result? Picking errors, lack of traceability, and administrative overload.

Heavy reliance on manual labor

Order preparation remains a highly manual task. But with the current shortage of qualified labor, this becomes a real challenge. Scaling operations during peak periods (Black Friday, holiday season, etc.) becomes increasingly difficult.

Lack of real-time visibility

Without a WMS (Warehouse Management System), it’s nearly impossible to track stock levels, order statuses, or delays in real time. This lack of visibility hinders proactive decision-making in warehouse operations.

How can order preparation be optimized?

📱 Implement the right WMS

An Android-based application like Satelix WMS helps digitize the entire process—from goods receipt to shipping, including order picking. It guides operators, reduces errors, and ensures full traceability.

🧭 Redesign flows and warehouse layout

Using zoning principles (placing high-turnover products closer to picking zones), clearly marked aisles, and logical product placement significantly streamlines order prep. A detailed warehouse map is key.

📊 Track key performance indicators (KPIs)

Error rates, average picking times, number of orders per operator—these metrics help identify areas for improvement and productivity gains.

🤖 Automate wherever possible

Conveyors, pick-to-light systems, or even partial automation can dramatically boost efficiency, even for mid-sized operations.

Order picking in the warehouse

On the ground, order picking is not just about retrieving products. It involves a set of structured operations that must be perfectly coordinated. In practice, efficient order picking relies on several key components:

Picking and packing 📦

Order preparation includes both item picking and packing. These two steps must be synchronized to avoid errors and ensure accurate shipments.

Multi-order picking 🔀

Grouping multiple orders helps optimize travel time and speed up preparation. However, it requires a system capable of correctly allocating items to the right parcels.

Task assignment to operators 👷

Assigning tasks to one or more operators helps balance workloads and improve overall warehouse performance.

Picking route optimization 🧭

A good WMS generates optimized picking routes, reducing unnecessary movement and significantly increasing productivity.

Batch / serial number management 🔢

Each pallet, parcel, or product can be uniquely identified using batch and/or serial numbers. This ensures full traceability throughout the supply chain, especially when working with carriers. It is particularly critical in industries such as food, pharmaceuticals, and cosmetics.

Logistics label printing 🏷️

Automating label printing (parcel, pallet, and shipping labels) saves time and reduces manual errors. Labels can be printed automatically or on demand, based on the packing list.

Carrier integration 🚚

Once the order is ready, data is directly transmitted to carriers: label generation, tracking number creation, shipment planning… everything is automated.

In conclusion…

Order preparation is a critical link in the logistics chain—often underestimated but essential to customer satisfaction and cost control. It requires structure, the right tools, and continuous improvement.

At Satelix, we support SMEs in optimizing their warehouse operations with an agile, mobile, and easy-to-deploy WMS solution.