In today's fast-moving warehouse environments, efficiency isn't just a goal—it’s a necessity. As order volumes grow and SKU variety expands, many warehouses are turning to smarter picking strategies to stay competitive. One such strategy gaining momentum is cluster picking.
So, what is picking in a warehouse context? Simply put, it’s the process of retrieving items from storage to fulfill customer orders. But how you pick can make or break your productivity.
That’s where cluster picking comes in. It’s a method designed to streamline operations by allowing a single picker to gather items for multiple orders at the same time, keeping each order separate using designated bins or containers.
What is Cluster Picking?
Cluster picking is a warehouse picking method where a worker picks items for multiple customer orders in a single pass through the warehouse, using separate bins, totes, or containers to keep each order organized. Unlike batch picking, where items are picked together and sorted later, cluster picking keeps orders separated from the start, reducing errors and post-pick sorting time.
In simple terms, it’s like doing multiple grocery orders at once: each basket represents a different order, and you walk the aisles only once.
This method is especially effective in high-throughput environments with many small-to-medium orders that share common items. It's often used in e-commerce, cosmetics, and retail industries where fulfillment speed and accuracy are critical.
Warehouse cluster picking is gaining traction as one of the most practical and scalable methods within the broader types of picking strategies. When combined with a modern WMS like Acumatica warehouse management, it becomes even more powerful, thanks to mobile scanning, real-time inventory guidance, and optimized route suggestions.
Here’s a quick cluster picking example:
A warehouse associate uses a cart with eight bins. Each bin represents a separate order. The WMS, such as Acumatica WMS, guides the picker through the most efficient path, prompting them where to pick items and into which bin to place them. Once all picks are completed, the orders are ready to pack—no extra sorting needed.
Why Use Cluster Picking in Your Warehouse?
Pick more orders with the same team
One picker handles 4–8 orders in a single trip instead of repeating the same route for each order.Cut walking time by up to 50%
Shared pick paths reduce redundant movement across the warehouse.Ideal for high SKU overlap
Works best when multiple orders include the same parts—common in auto parts, cosmetics, and electronics.No post-pick sorting needed
Each order stays in its own bin from the start, ready for packing.Fewer mis-picks
Barcode scanning and mobile guidance in Acumatica WMS keep picking accurate and efficient.Faster packing process
Orders arrive at the packing station already separated and verified.
Used by NASA: Cluster picking isn’t just for e-commerce—NASA has used cluster picking techniques in their logistics operations to efficiently handle mission-critical, small-volume, high-variety components.
Typical Tools and Equipment
Implementing doesn’t require a massive tech overhaul—but the right tools can make it dramatically more effective and scalable, especially when paired with a capable warehouse management system like Acumatica WMS.
Multi-Bin Picking Carts
The heart of cluster picking is separation. A multi-bin cart—often with 4, 6, or even 12 labeled compartments—allows a picker to keep each order organized while moving through the warehouse. Some carts include color-coding or light-assisted bins for extra guidance.
Mobile Devices with Barcode Scanners
Each pick should be verified in real time. Barcode scanning devices or rugged warehouse smartphones help pickers confirm they're placing the right item in the right bin. Acumatica warehouse management supports mobile scanning through its native mobile WMS app.
WMS with Cluster Picking Logic
A modern WMS like Acumatica WMS plays a crucial role in making cluster picking efficient. It can:
Automatically group orders that share common SKUs or locations
Generate optimal pick paths
Assign bins dynamically and track which item belongs to which order
Provide real-time error alerts and completion status
Pick-to-Light or Voice Picking (Optional)
For high-volume operations, adding pick-to-light systems or voice-directed picking can further improve speed and reduce training time. While not required, these tools enhance accuracy and simplify multi-order workflows.
Cluster Picking in Action: Real-World Example
In an automobile spare parts warehouse, orders often include a mix of small, fast-moving items (like filters or gaskets) and bulky parts (like brake discs or mirrors). A picker receives six orders grouped by Acumatica WMS based on shared SKUs and zone proximity.
By the time the picker returns, six customer orders are ready for packing—fast, accurate, and efficient, even with thousands of SKUs and complex inventory.
Using a six-bin cart and a mobile scanner, the picker moves through the aisles once, grabbing shared items like spark plugs and brake pads, and placing them into the correct bins as directed by the system. Each order remains separated, and no post-pick sorting is needed.
Benefits Recap
50
–
75%
more efficient
picking per shift
No extra sorting — orders go straight from picking to packing
Is Cluster Picking Right for You?
Not every warehouse needs cluster picking, but if your numbers look like this, it could be a game changer:
Daily Orders:
100–1 000 per day
SKU Overlap:
30–60% of orders
include the same parts
Warehouse Size:
Medium footprint
(1,000–5,000 m²)
Order Lines:
3–15 items per order
Picker Count:
3–20 active pickers
Rule of thumb:
If your pickers touch the same bin more than once per shift for different orders, cluster picking will likely save time and money.
How to Get Started with Cluster Picking with Acumatica WMS
Cluster picking is fully supported in Acumatica WMS, and rolling it out is straightforward. Here’s how to get started step by step using standard Acumatica objects:
1 Analyze Your Order Patterns
Use the Sales Orders (SO301000) screen to review order volumes, lines per order, and common SKU combinations. High SKU overlap across orders is ideal for cluster picking.
2 Configure Cluster Picking Settings
Go to Warehouse Management Setup (WMS101000) to:
● Enable cluster picking
● Define cluster size (e.g., 4–8 orders per wave)
● Set pick route optimization parameters
You can also manage picking templates under WMS Pick Settings to align pick bins with standard picking carts.
3 Use Pick List and Pick Worksheet Screens
Generate multi-order pick documents using:
● Pick List (SO302000) – shows picking instructions per order
● Pick Worksheet (WMS201000) – consolidates clustered picks across multiple sales orders and assigns bins
4 Equip Your Pickers
Assign pickers to clusters via the Picker Assignment (WMS203000) screen. Each picker is guided through optimized pick paths using Acumatica’s Mobile App on a rugged device or tablet.
Each scan confirms the item, validates bin placement, and updates Inventory Allocations (IN202500) in real time.
5 Monitor and Optimize
Use dashboards or the Pick Performance Report to track:
● Pick the completion time
● Cluster efficiency
● Error rates (validated through shipment confirmations)
Adjust cluster sizes and picking zones based on actual data, and scale the process as needed.
Start cluster picking with fast-moving inventory in a dedicated zone. Use Inventory Preferences (IN101000) to assign those items to a cluster-priority warehouse location class.
tip:
6 Conclusion
Start cluster picking in Acumatica WMS by enabling it in Warehouse Management Setup, generating Pick Worksheets across multiple Sales Orders, assigning pickers via Picker Assignment, and guiding them through efficient routes using the Acumatica Mobile App.
Frequently Asked Questions (FAQ)
How do I measure whether my current picking process is inefficient enough to justify switching to cluster picking?
Look for these signs:
Staff manually sort orders after picking, slowing the packing speed.
Quick check: If more than 20% of orders are touched more than once during picking or require post-sorting, cluster picking will likely bring measurable efficiency gains.
Can cluster picking be combined with other strategies like wave or zone picking in Acumatica WMS?
Acumatica supports hybrid picking strategies.
You can:
Combine cluster + wave:
Group picks based on carrier deadlines and still assign them as clusters.
Combine cluster + zone:
Assign pickers to zones but allow them to fulfill multiple orders per zone using cluster logic.
Acumatica Setup Tip:
In Pick Worksheet (WMS201000), you can filter by wave or zone, and then cluster compatible orders — all managed within standard logic.
What’s the actual time or cost savings per order if I switch to cluster picking?
Typical savings:
● 30–50% reduction in walking time per order
● 50–75% boost in picking productivity (orders picked per hour)
● 20–40% fewer packing errors when combined with barcode scanning
A team of 5 pickers previously processed 500 orders/day. After switching to cluster picking (6–8 orders per run), the same team hit 750+ orders/day with fewer errors, without hiring new staff.
Do I need to reconfigure my warehouse layout or purchase new equipment to start?
Not necessarily. Most companies start with:
Existing carts retrofitted with color-coded bins (or even cardboard boxes)
Standard barcode scanners + mobile devices (already supported in Acumatica WMS)
No layout changes — just smarter route logic and order grouping
Start small: Test cluster picking in 1 zone with your fastest-moving SKUs using a 4–6 bin cart. Then expand.
How hard is it to set this up in Acumatica if I’ve never used cluster picking before?
It’s moderately easy, especially if you’re already using Acumatica WMS for basic picking.
Steps overview:
Go to Warehouse Management Setup (WMS101000) → enable cluster picking
Set cluster size limits (e.g., max 6 orders per run)
Use the Pick Worksheet (WMS201000) to group orders
Assign pickers via Picker Assignment (WMS203000)
Train staff using Acumatica’s mobile app
If needed, a consultant can configure this in under 8–12 hours, including pilot setup and picker training.