Order picking

Order picking

Order picking – forklifts

Efficient order picking plays a crucial role in the smooth functioning of warehouse operations. It involves accurately identifying, locating, and retrieving items from storage to fulfill customer orders. Ensuring that this process is efficient can greatly impact overall productivity and customer satisfaction.

Forklifts enable warehouse staff to efficiently move heavy and bulky items that would otherwise be time-consuming and physically demanding. This leads to increased productivity as more orders can be picked and fulfilled within a shorter period. The use of forklifts also allows for a more organized layout, as items can be stacked higher and in a compact manner, optimizing storage space.

Order picking methods

There are various types of order picking methods commonly employed in this process.

One method is called “piece picking,” where individual items are manually picked and placed onto pallets or bins by forklift operators.

Another method is “case picking,” where entire cases of products are picked and loaded onto pallets or containers.

Additionally, there is the “pallet picking” method, where entire pallets are retrieved and transported to loading areas. The choice of method depends on factors such as order volume, product characteristics, and facility layout.

Technology plays a significant role in enhancing both the accuracy and speed of order picking operations.

Factors Affecting Forklift Order Picking Efficiency

Several factors play a significant role in determining the efficiency of this process. In this article, we will discuss the importance of proper planning and organization, the analysis of layout and design considerations, as well as the impact of product categorization, storage systems, and labeling on efficiency.

Proper planning and organization

This involves creating a detailed plan that outlines the most efficient routes for picking orders and organizing the items in a logical sequence. By planning, warehouses can minimize travel time, reduce the chances of errors, and increase the overall productivity of the forklift operators.

Analysis of layout and design

Warehouses need to optimize their layout to ensure that forklift operators have clear paths and easy access to all the necessary areas. Design considerations such as aisle width, rack spacing, and the arrangement of storage areas can greatly impact the efficiency of order picking. By analyzing the layout and making necessary adjustments, warehouses can significantly improve overall performance.

Product categorization, storage systems, and labeling

Properly categorizing products and storing them in an organized manner allows for easier identification and retrieval. Moreover, implementing efficient storage systems, such as high-density racking or automated storage and retrieval systems, can save time and effort for forklift operators. Additionally, clear, and accurate labeling of products and storage locations minimizes confusion and reduces the chances of errors during order picking.

Order Picking Efficiency

To improve the efficiency of forklift order picking, it is essential to embrace and utilize advanced technologies.

Forkfleet – Optimizing Order Distribution with Forklift Tablets

Mobile system

By employing tablets securely mounted inside forklifts, this innovative technology streamlines task management and enhances productivity throughout the facility.

Cost reduction

With tasks conveniently displayed on these sturdy tablet holders, any available operator can readily pick up a job at any given moment. The system also offers advanced analytics, contributing to workflow optimization and reducing costs by an average of 30%.

Smart solution

The principle behind Forkfleet is simple yet highly effective. Each forklift is equipped with a tablet that acts as a centralized hub for all operational tasks. These tablets are securely mounted within robust holders, ensuring they stay in place during the dynamic movements of the forklifts.


This real-time accessibility allows operators to immediately begin executing the assigned task without the need for manual paper-based instructions or waiting for verbal communication.

The seamless integration of tablets within forklifts significantly improves response time and ensures that orders are processed swiftly. As a result, warehouse operations become more agile, allowing for a quicker turnaround of tasks, and increased overall productivity.


In addition to the immediate benefits of efficient task management, Forkfleet offers comprehensive analytics capabilities. The system collects data on various aspects of the warehouse operations. This data is then analyzed to identify areas for improvement.

By harnessing the power of real-time data analytics, Forkfleet empowers warehouse managers to make informed decisions and implement targeted strategies. This data-driven approach leads to higher operational efficiency and ultimately translates into cost savings for the company. On average, businesses utilizing Forkfleet experience a significant reduction in costs, with a noticeable decrease of around 30%.

RFID (Radio Frequency Identification)

By attaching RFID tags to products and equipping forklifts with RFID readers, the process of locating and picking items becomes significantly faster and more accurate.


Automated systems, such as conveyor belts and robotic arms, can greatly speed up the movement and sorting of products within a warehouse. By reducing the need for manual intervention and human error, automation helps to streamline the entire order picking process.

Batch picking and zone picking techniques

Batch picking involves picking multiple orders at once, thereby minimizing travel time and maximizing productivity. Zone picking, on the other hand, assigns specific areas or zones to individual forklift operators. This ensures that each operator focuses solely on their assigned zone, resulting in a more organized and efficient order picking process.

Data analytics play a crucial role in identifying bottlenecks and streamlining processes. By analyzing data related to order volumes, product popularity, and historical picking times, businesses can identify potential issues and take proactive measures to address them. Data analytics provide valuable insights into optimizing warehouse layouts, reorganizing picking routes, and determining the most efficient allocation of resources.

Order Picking Safety

Forklift operators should be trained on how to operate the equipment safely, including proper maneuvering, loading, and unloading techniques. Regular refresher courses should be conducted to keep the knowledge fresh in their minds.

Identifying common hazards and potential accidents is another essential aspect of maintaining a safe work environment during order picking. Some common hazards include blind spots, poor visibility, uneven surfaces, and unstable loads. Workers should be made aware of these risks and provided with strategies to mitigate them.

Warning lines forklift

Warning lines are used to mark the safety area around a vehicle, ensuring that pedestrians maintain a safe distance. These lines are prominently displayed using LED lamps or lasers located on the sides and back of the vehicle. By clearly indicating the minimum distance that should be maintained, this product enhances safety for pedestrians near the vehicle. Additionally, the visibility of these warning lines serves as a visual reminder for both pedestrians and drivers to exercise caution and be mindful of their surroundings. Ultimately, the use of warning lines can prevent accidents and promote a safer environment for everyone involved.

Warning lights forklift

LED lights connected to the vehicle’s gears are installed at the front, back, and upper part of the vehicle. These lights illuminate signs on the ground, indicating the direction the vehicle is traveling in. This innovative feature provides pedestrians with an early warning of an approaching vehicle, allowing them ample time to react.

The displayed signs can either be fixed or programmed to flash intermittently. This flashing option significantly enhances visibility, ensuring that pedestrians can easily spot the approaching vehicle even in busy surroundings or low light conditions.

By incorporating these warning lights into vehicles, several benefits arise. Firstly, the increased visibility aids in preventing accidents and collisions between pedestrians and vehicles. The early warning system allows both parties to anticipate each other’s movements, reducing the risk of potentially dangerous situations.

Secondly, the use of LED lamps not only provides a clear indication of the vehicle’s direction but also serves as an effective communication tool. Pedestrians can quickly interpret the displayed signs and adjust their actions, accordingly, further promoting safety.

Schedule a presentation, learn about our system and ask us any question you have about forklift optimization.

Why is it worth working with us?

Free audit

During a free consultation, we will listen to your needs. Then we will find and customize a solution that will be effective for you.

No need for integration

The system operates independently of other systems in the company. It does not use the company's network. It does not require involvement of the client's IT department.


The system performs multiple tasks. It assigns tasks to forklift operators, provides analytical data to leaders, organizes and increases the efficiency of intralogistics.

Budget solution

No large initial investment. Settlements in the form of a monthly subscription. Option to cancel at any time.

Proven system

Successfully implemented system for many clients from around the world. In every case of implementation, it resulted in increased efficiency.

Specific savings

Implementing our clients' system reduced forklift fleet costs by an average of 30%. Be the father of financial success in your company. Take advantage of the opportunity for savings!

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