When it comes to order fulfilment, speed and accuracy don’t happen by accident they’re engineered. And one of the biggest contributors to smooth operations is your pick and pack location strategy. It’s the backbone of every warehouse workflow and the single most important factor that determines how quickly orders get out the door.
If workers don’t know EXACTLY where each product is stored, picking slows down, accuracy drops, and customers feel the pain. But when your warehouse locations are mapped, labelled, and optimised, the entire pick and pack system becomes faster, cleaner, and more predictable.
Let’s dive into how pick and pack locations work, why they matter, and how to optimise yours.
What Is a Pick and Pack Location?
A pick and pack location is a defined, organised space in a warehouse where products are stored for easy retrieval during the picking process. It’s usually assigned a code such as:
Aisle → Rack → Shelf → Bin
Example: A3-R2-S1-B6
This code tells workers exactly where the item lives, just like a home address.
A properly set pick and pack location system includes:
Aisles
Racks
Shelves
Bins
Zones
Fast-moving products near dispatch
Slow-moving products in deeper storage
This structured layout dramatically improves fulfilment speed.
Why Pick and Pack Location Matters
Warehouses that don’t optimise their pick and pack locations struggle with:
Workers searching for items
High picking errors
Slower fulfilment
Crowded paths
Inconsistent workflows
Poor inventory visibility
But when locations are well organised, everything changes.
Key benefits include:
Faster picking times
Workers walk less and pick more.
Improved accuracy
Exact locations reduce mistakes.
Smooth warehouse flow
No clogged aisles or backtracking.
Better inventory control
Stock checks become simpler and more accurate.
Higher fulfilment output
Teams handle more orders per hour.
A strong pick and pack location system is a game-changer.
How Pick and Pack Locations Are Structured
Warehouses typically divide pick and pack locations into logical sections:
1. Fast-Mover Zones
High-demand products placed near packing stations to save time.
2. Slow-Mover Zones
Items that rarely sell stored further away.
3. Bulk Storage
Large cartons or pallets kept in separate areas.
4. Picking Shelves
Small, frequent items placed at ergonomic heights.
5. Temperature-Controlled Zones
For food, medical, and chemical products.
6. Fragile-Area Locations
Protected shelves to avoid breakages.
The layout reflects product demand and reduces the physical workload of warehouse staff.
How Pick and Pack Location Systems Work
Here’s the typical flow from order to dispatch:
Step 1: System Creates a Pick List
The warehouse management system (WMS) lists exact item locations.
Step 2: Worker Follows Location Codes
They move through the warehouse in the fastest route.
Step 3: Barcode Verification
Location and item barcodes confirm accuracy.
Step 4: Items Move to Packing
The packing station prepares the final shipment.
Step 5: Dispatch
Labels printed, parcels closed, and orders shipped.
This process is only efficient when location data is clean, accurate, and easy to follow.
Best Practices for Optimising Pick and Pack Locations
If you want smoother fulfilment, these strategies make a massive difference:
Use logical naming conventions
A1 → Aisle
02 → Rack
05 → Shelf
Place fast-selling items near packing areas
Saves walking time and increases output.
Group similar items together
Electronics with electronics, tools with tools, safety gear with safety gear.
Use bin labels and colour coding
Instant visual recognition speeds up picking.
Avoid placing heavy items above shoulder height
Safety + efficiency.
Review product velocity monthly
Update locations based on what sells fast or slow.
Use a WMS for real-time tracking
Digital systems eliminate confusion and misplaced inventory.
Warehouses that optimise locations often cut picking times in half.
Common Mistakes in Pick and Pack Location Planning
Many inefficiencies come from poor planning. Common mistakes include:
Random product placements
No dedicated zones
Unlabelled bins or racks
Mixing fast and slow-moving items
Overcrowded aisles
Poor lighting
Ignoring worker walking paths
Solve these issues, and your warehouse instantly feels more organised and productive.
Technology That Improves Pick and Pack Locations
Modern logistics uses smart technologies to enhance accuracy:
Barcode scanners
RFID tags
AI-driven warehouse route optimisation
Pick-to-light systems
Mobile handheld devices
Digital maps showing shelf locations
Automated storage and retrieval systems
To explore more logistics tech insights, use this DoFollow resource:
https://share.google/lgtCmZysrDNTmlqtf
Internal Links to Boost Warehouse Understanding
Carewell Group
https://carewellgroup.com.au/
Custom Packaging Solutions
https://carewellgroup.com.au/custom-solutions/
Warehouse Storage Solutions
https://carewellgroup.com.au/storage-solution/
Packaging Supplies
https://carewellgroup.com.au/category/packaging/
Sustainability in Packaging
https://carewellgroup.com.au/sustainability/
These internal links help readers explore storage optimisation, packaging, and operational improvements related to pick and pack processes.
Why Pick and Pack Location Optimisation is Essential
If you want:
Fast fulfilment
Zero picking errors
Lower labour costs
Clear organisation
Satisfied customers
Scalable warehouse operations
Smart location planning turns chaos into efficiency and transforms fulfilment into a predictable, high-performance system.
Ready to Improve Your Warehouse Operations?
If you want a smarter, more accurate pick and pack location system, starting with the right warehouse planning and storage solutions is key and Carewell Group can help with everything from packaging to logistics improvement.
Request a Quote
Carewell Group Pty Ltd
Unit 27/191, Mccredie Road, Smithfield, NSW 2164
Phone
+61 0477 123 699
Email
sales@carewellgroup.com.au
info@carewellgroup.com.au
logistics@carewellgroup.com.au
