What Causes Warehouse Picking Delays, And How Can You Fix Them?
- Westbow Systems
- 11 hours ago
- 4 min read
Warehouse picking is one of the most important processes in any distribution operation. It’s also one of the most expensive. Research consistently shows that order picking can account for 50–60% of total warehouse operating costs.
When picking slows down, everything else does too, shipping delays, missed deadlines, frustrated customers, and higher labor costs.
At Westbow Systems, we see this challenge often across warehouses and distribution centers throughout Western Canada. And the truth is, picking delays rarely come from one single problem. They’re usually the result of layout decisions, storage design, workflow inefficiencies, and outdated systems working against your team.
The good news? Most picking delays are solvable with the right storage strategy.
Let’s look at the most common causes.
Inefficient Warehouse Layout Increases Travel Time
In many warehouses, the biggest delay isn’t the picking itself, it’s the time spent walking.
Travel time can represent more than half of total picking time. When warehouse layouts aren’t designed for picking efficiency, workers spend unnecessary time moving between locations.
Common layout issues include:
High-demand items stored far from packing areas
Poor aisle design creating congestion
Inefficient storage zones
Bottlenecks between forklifts and pickers
Over time, these inefficiencies compound into serious productivity losses.
At Westbow Systems, we work with companies to redesign their storage layouts so that high-velocity inventory sits where it makes the most operational sense.
Strategic racking placement, optimized aisle widths, and logical pick zones can dramatically reduce travel time.
If your team spends more time walking than picking, it may be time to rethink your storage layout.
Poor Inventory Slotting Creates Search Time
Slotting, the strategic placement of inventory, is one of the most overlooked drivers of picking efficiency.
Without proper slotting, workers may need to:
Search for misplaced inventory
Visit the same aisle repeatedly
Navigate inefficient pick paths
Disorganized storage also increases the risk of mispicks, which adds even more delays when orders must be corrected.
The right storage systems make slotting easier. Solutions such as selective pallet racking, carton flow systems, and modular shelving help organize products according to demand frequency, size, and picking method.
At Westbow Systems, we help warehouses design storage systems that support logical inventory placement and faster retrieval.
Better slotting means fewer search delays and faster order fulfillment.
Labor and Training Challenges Slow Productivity
Even with good storage systems, warehouse picking remains a labor-intensive process.
Worker productivity can vary significantly depending on:
Training quality
Experience levels
Staffing availability
Workflow clarity
When teams are understaffed or constantly onboarding new employees, productivity naturally drops. Inconsistent picking methods can also create bottlenecks across shifts.
One way to reduce reliance on complex training is to design a warehouse that makes efficient work intuitive.
Clear pick zones, organized shelving systems, and consistent labeling reduce decision-making and allow employees to work faster with fewer errors.
At Westbow Systems, we design storage environments that support simple, repeatable workflows, making it easier for teams to stay productive even during staffing changes.
The right storage infrastructure supports your people instead of slowing them down.
Inefficient Picking Methods Increase Travel
Another common source of delays comes from picking strategy.
Warehouses typically use several picking methods, including:
Single-order picking
Batch picking
Zone picking
Wave picking
When the wrong method is used, workers may repeatedly travel to the same locations for different orders, dramatically increasing travel time.
For example, batch picking or zone picking can significantly reduce movement in high-volume operations, but only when the warehouse layout supports it.
That’s where storage planning becomes critical.
At Westbow Systems, we help businesses align their warehouse storage systems with their order profiles and picking strategies, ensuring that storage supports operational efficiency rather than working against it.
The right picking method works best when the storage layout is built to support it.
Outdated Technology Slows Picking Operations
Technology has transformed warehouse operations, but many facilities still rely on outdated processes.
Without modern tools like Warehouse Management Systems (WMS), barcode scanning, voice picking, or pick-to-light systems, pickers often rely on manual lists and visual searches.
These processes increase:
Picking errors
Search time
Order processing delays
However, technology alone doesn’t solve the problem. Even advanced systems perform poorly if the storage layout and inventory organization aren’t optimized.
At Westbow Systems, we frequently help clients prepare their facilities for technology upgrades by first improving storage infrastructure, accessibility, and pick paths.
The result is a warehouse that can fully benefit from modern digital tools.
Technology works best when the physical environment supports it.
Growing Order Complexity Adds Pressure
E-commerce has changed warehouse operations dramatically.
Instead of shipping large quantities of single products, warehouses now process many smaller orders containing multiple items stored across different locations.
This increases:
Travel distance
Pick complexity
Order consolidation time
Facilities originally designed for bulk distribution often struggle to keep up with these new fulfillment demands.
That’s why many companies are redesigning their storage systems to support higher order volumes and faster picking workflows.
At Westbow Systems, we specialize in helping Western Canadian businesses adapt their warehouses to modern order profiles through smart storage design and workflow optimization.
Solving Picking Delays Starts With Better Storage Design
Warehouse picking delays rarely come from a single issue. They are usually the result of layout inefficiencies, poor slotting, labor challenges, outdated processes, and evolving order demands.
But when these challenges are addressed strategically, the improvements can be dramatic.
Faster picking.
Lower labor costs.
Better order accuracy.
Happier customers.
At Westbow Systems, we help businesses across Western Canada design storage environments that improve workflow, maximize space, and support faster fulfillment.
If picking delays are slowing your operation, the solution may start with your storage system.
