“Pick-by-Scan” is a warehouse picking method where each step is confirmed by scanning barcodes/QR codes (e.g., item, bin, lot, serial number). A mobile app on handhelds or wearables guides workers, validates picks against the WMS/ERP in real time, and thereby reduces errors, search time, and rework. Pick-by-Scan is flexible (single, batch, wave) and complements or substitutes pick-by-voice and pick-to-light.
Guided pick workflows: Step-by-step instructions with location, item, and quantity confirmation via scan.
Validation & error prevention: Checks for item number, bin, EAN/GS1 codes, check digits; blocking on mismatches.
Real-time inventory & order sync: Online/offline synchronization with WMS/ERP; immediate stock postings.
Lot/serial & expiry/FEFO: Mandatory capture and validation of lots, serials, and expiration dates including FEFO rules.
Picking methods: Single-order, multi-order/batch, wave, zone, and series picking.
Route & travel optimization: Dynamic path planning, prioritization by SLA, cut-off time, or carrier.
Exceptions & substitutions: Short-pick reasons, automatic alternatives, quarantine/hold workflows.
Quality & compliance: Inspection and counting, photo/notes, checklists, audit trail with timestamps.
Inventory & cycle counting: In-process counts (ad hoc/scheduled) including variance handling.
Labeling & printing: On-demand printing of shipping, consolidation, and relocation labels.
Packing & shipping integration: Handover to packing, ship-ready confirmation, carrier/TMS integration.
Device & usability features: Support for handhelds, ring/hands-free scanners, glove scanners; large touch UI, haptic/audio feedback, multilingual UI, dark mode.
KPIs & monitoring: Productivity KPIs (picks/hour, error rate), heatmaps, live dashboards and reporting.
Interfaces & standards: REST/GraphQL APIs, GS1 parsing (AIs), 1D/2D codes, SSO/role-based access, MDM/device management.
An e-commerce fulfillment center uses guided scan workflows to cut mis-picks and reduce onboarding time for new staff.
A food wholesaler applies FEFO pick-by-scan to comply with expiry rules and lower write-offs.
A medical devices distributor captures serial numbers to ensure traceability and meet UDI requirements.
A spare-parts warehouse deploys multi-order picking with ring scanners to minimize travel and hit carrier cut-offs.
A DIY retailer fulfills click-and-collect orders by scanning bins and items, consolidating orders, and printing pickup labels.
