Warehouse Order Picking and Fulfillment Workflow

Estimated Time: 2-4 hours per order batch | Difficulty: Intermediate | Team Size: 2-5 warehouse staff A complete 9-step warehouse order fulfillment workflow covering picklist generation, picker assignment, item retrieval, barcode verification, quality inspection, packing, shipping label creation, and customer notification. This template ensures accurate order fulfillment with full traceability from order receipt through final shipment. Industry: Logistics, Warehousing, E-commerce, Retail Distribution Use case: Order fulfillment, inventory picking, shipping operations, warehouse management

9 steps

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Process steps

Generate warehouse picklist from pending orders

2 hours from previous step

task

Create the picking list from your warehouse management system (WMS) or order queue. Group orders by warehouse zone or aisle to minimize picker travel time and improve efficiency. Send the picklist to mobile RF scanners or print for manual picking. Flag any backorders, out-of-stock items, or special handling requirements before dispatching pickers to the floor.

Assign warehouse picker to order batch

2 hours from previous step

task

Assign an available warehouse picker to this order batch based on current workload, zone expertise, and picker performance metrics. Check real-time floor availability and order priority levels. Consider special handling requirements such as hazmat, fragile items, or temperature-sensitive products when making assignments. Document the assignment for accountability and performance tracking.

Prepare picking cart and warehouse equipment

3 hours from previous step

task

Retrieve an available picking trolley or cart from the staging area. Inspect the trolley for cleanliness and proper working condition. Gather all required equipment including RF scanner, barcode labels, picking totes, and any protective gear. Verify battery levels on mobile devices are sufficient for the picking route. Report any equipment issues to maintenance before proceeding.

Scan totes and verify item barcodes for accuracy

4 hours from previous step

task

Scan each tote barcode to link it to the corresponding order in the WMS. Scan every item barcode as you place it in the tote to ensure picking accuracy. The system will alert you immediately to any SKU mismatches, wrong quantities, or substitution requirements. Document and report any damaged items, missing inventory, or discrepancies to your supervisor for immediate resolution.

Review and verify customer order details

4 hours from previous step

task

Confirm the order is complete, accurate, and ready for fulfillment before starting the picking process. Review for any special instructions, rush shipping requests, gift wrapping, or custom notes from sales or customer service. Verify shipping address and delivery method. Catching order issues at this stage prevents costly rework, returns, and customer complaints downstream.

Pick ordered items from warehouse inventory locations

6 hours from previous step

task

Navigate an optimized path through the warehouse to retrieve items from their designated bin locations. Use pick lists or mobile RF scanners to locate each SKU. Verify quantities and product codes as you pick to prevent errors. One wrong item can cost more than the entire order value in returns, reshipping, and customer dissatisfaction. Flag any inventory discrepancies for cycle count review.

Perform quality inspection and pack shipment securely

8 hours from previous step

task

Inspect each item before packing for damage, correct model number, and included accessories. Verify the order matches the packing slip exactly. Pack items securely using appropriate box size and protective materials such as bubble wrap, air pillows, or packing paper. Fragile and high-value items require extra protection. Include the packing slip, any promotional inserts, and gift messaging when applicable.

Generate shipping label and verify carrier details

10 hours from previous step

task

Create the shipping label based on the customer-selected carrier and shipping method. Verify the destination address is complete, correct, and deliverable. Weigh the package accurately using calibrated scales to prevent carrier surcharges and delivery delays. Select appropriate service level for priority or guaranteed delivery windows. Apply the label securely and scan to confirm tracking number assignment.

Update order status and send customer shipment notification

12 hours from previous step

task

Update the order status to shipped in your order management system and WMS. Send the tracking number and estimated delivery date to the customer via email or SMS notification. Move the completed package to the outbound staging area for carrier pickup. Update inventory counts if your system does not automatically decrement on shipment. Log any order notes for customer service reference.