Pick-by-Scan
Also: Pick by Scan, Scannerkommissionierung, scannerbasierte Kommissionierung, Scan-Kommissionierung, Pick-by-Scanner, PBS
AI-generated
Pick-by-Scan is a scanner-assisted picking method in which employees capture storage locations and items using a mobile scanner, confirming each picking step within the system. The method significantly improves data quality and traceability in the warehouse.
Key facts
- Pick-by-Scan confirms every pick step by scanning both the location code and the item code, preventing mispicks at an early stage.
- The method creates a seamless digital posting trail that supports batch and serial number traceability.
- Seamless Wi-Fi coverage throughout the warehouse is a fundamental technical prerequisite for uninterrupted Pick-by-Scan operations.
- Missing or damaged barcodes on storage locations or items are the most common operational source of errors in Pick-by-Scan.
- Compared to Pick-by-Light and Pick-by-Voice, Pick-by-Scan is generally easier to implement in terms of hardware requirements and initial setup.
What is Pick-by-Scan?
Pick-by-Scan refers to a picking process in which each item removal is confirmed by scanning a barcode or other machine-readable code. The warehouse management system (WMS) guides the picker through the order, specifies the storage location and item quantity, and waits for scan confirmation before releasing the next step. If the scanned code does not match the system specification, the device immediately triggers an alert. This creates a seamless digital audit trail of every pick.
How does Pick-by-Scan work in practice?
The WMS transmits the picking order to a mobile data entry device — typically a handheld scanner, an MDE terminal, or a wearable scanner worn on the wrist or finger. The operator navigates to the displayed storage location, scans the location code (e.g. a barcode or QR code on the shelf), picks the specified quantity, and then scans the item code on the packaging. Only after a successful dual verification — location and item — does the system post the pick and display the next step.
In addition to classic single-line picking, Pick-by-Scan can also be used for the following processes:
- Goods receipt and put-away with batch assignment
- Serial number capture for products subject to traceability requirements
- Stock transfers and inventory counts
- Batch picking, where one operator processes multiple orders simultaneously
The required Wi-Fi infrastructure must provide seamless coverage throughout the entire warehouse, as connection interruptions disrupt the process. Battery capacity, device protection ratings (drop and dust resistance), and ergonomic handling during shift operations are critical operational factors.
What should you look for when choosing a solution?
Several aspects need to be evaluated when implementing Pick-by-Scan. On the software side, the WMS must support process control, error handling, and device management (MDM). Licensing cost models vary considerably between vendors and should be calculated over the entire operational period. On the hardware side, in addition to device type and protection rating, battery swap concepts and repair turnaround times are also relevant. Compared to Pick-by-Light or Pick-by-Voice, Pick-by-Scan is a robust, widely adopted method with low barriers to entry, but it requires consistent master data maintenance: incorrect or missing codes lead to process interruptions. Whether Pick-by-Scan, Pick-by-Voice, or a combination of both methods is more suitable depends on assortment size, item weight, noise levels, and hands-free operation requirements — no blanket recommendation can be made here.
Related terms
- AKL
An Automated Small Parts Warehouse (AKL) is a fully mechanized storage system for bins, trays, or cartons that automates the goods-to-person process using aisle-captive storage and retrieval machines or shuttles.
- Akustische Kommissionierung
Acoustic order picking is a paperless picking method in which warehouse employees receive pick instructions via voice and confirm each step using spoken responses. Both hands remain free throughout the actual picking process.
- Automatisches Kleinteilelager (AKL)
The Automated Small Parts Warehouse (AKL) is a fully automated storage system for totes, trays and small parts, in which storage and retrieval operations are performed without manual intervention by stacker cranes or shuttle systems.
- Barcode
A barcode is a machine-readable optical code that represents information as a pattern of bars and spaces or as a two-dimensional matrix. It enables the automatic identification of items, load carriers, and documents along the entire supply chain.
- Barcodescanner
A barcode scanner is an optical reading device that captures printed barcodes and converts them into machine-readable data. It is used in intralogistics for the seamless identification of goods, load carriers, and storage locations.
- Batch-Kommissionierung
Batch picking is a method in which multiple customer orders are consolidated into a single pick run. This allows the picker to travel one route while simultaneously covering positions from different orders.
- Beleglose Kommissionierung
Paperless picking refers to the assembly of orders in the warehouse without paper pick lists, where all instructions are transmitted digitally via terminals, displays, voice, or optical signals.
- Chargenrückverfolgung
Batch traceability refers to the complete and uninterrupted trackability of products and materials along the supply chain based on their batch assignment. It enables companies to quickly identify and selectively block all affected quantities in the event of a quality issue or recall.
- Datenfunkgeräte
Data radio devices are mobile or stationary hardware components that transmit data wirelessly via radio protocols such as WLAN or cellular. In warehouse and transport environments, they form the operational interface between employees and IT systems such as WMS or ERP.
- Datenfunkterminal
A data radio terminal is a mobile device for wireless data capture and transmission in the warehouse, combining a display, input, and scanner in one unit. It typically communicates with a warehouse management system via Wi-Fi and supports processes such as goods receipt, picking, and inventory counting.
