Pick pack and pass SAP EWM has become one of the most efficient methods for managing large-scale, multi-stage warehouse fulfilment in modern distribution centres. As customer expectations for speed and accuracy increase, warehouses are constantly searching for ways to eliminate bottlenecks, streamline picking, and reduce errors. SAP Extended Warehouse Management (EWM) offers exactly that especially through its Pick-Pack-Pass (PPP) strategy.

This guide walks you through how the process works, why businesses rely on it, and how it dramatically improves order accuracy and speed inside high-volume warehouses.

What Is Pick Pack and Pass SAP EWM?

In SAP EWM, Pick Pack and Pass is a fulfilment strategy designed for warehouses with zone-based picking. Instead of one worker collecting an entire order from every zone, multiple workers in different zones handle only their assigned sections, passing the handling unit (HU) or tote through each stage until the order is complete.

This method improves efficiency, reduces walking time, and supports high-throughput operations.

Key Components of Pick Pack and Pass

– Multiple warehouse zones
– Conveyor or manual pass-through points
– Handling Units (HUs) or totes
– Real-time scanning
– Multi-stage task management
– SAP EWM system-driven workflows

How Pick Pack and Pass SAP EWM Works

Here’s the step-by-step breakdown of the PPP process inside SAP EWM:

Step 1: Order Creation & Task Generation

Customer orders arrive from ERP or ecommerce systems. SAP EWM automatically creates Warehouse Orders (WOs) and assigns tasks to the correct zones.

Step 2: Zone-Based Picking Begins

Each picker works within their designated zone, scanning items into the handling unit. No one moves outside their zone—this alone saves tons of walking time.

Step 3: Passing to the Next Zone

Once items for a zone are complete, the HU is either manually moved or routed via conveyor to the next zone.

Step 4: Additional Items Added

The next picker adds items from their zone, ensuring correct quantities and scanning accuracy.

Step 5: Packing Preparation

Depending on the system setup, packing may occur at the end or partially during the process.

Step 6: Final Dispatch

Completed orders move to shipping, where they are labelled, sorted and dispatched.

SAP EWM updates inventory, task statuses and completion data in real time.

Why Warehouses Use Pick Pack and Pass SAP EWM

1. Massive Productivity Boost

Pickers stay in small zones, dramatically cutting walking time.

2. Optimised for High Order Volumes

Perfect for ecommerce, retail and FMCG companies processing thousands of daily orders.

3. Better Accuracy

Each zone has specialised pickers familiar with SKUs, reducing errors.

4. Automation-Friendly

Works perfectly with conveyor belts, pick-to-light, voice picking, and robotics.

5. Real-Time Visibility

Supervisors get live insights into bottlenecks, progress and workloads through SAP dashboards.

Industry Use Cases

Pick pack and pass SAP EWM is commonly used in:
– Ecommerce fulfilment centres
– Consumer goods warehouses
– Apparel and fashion logistics
– Electronics and accessories warehouses
– Pharma and healthcare distribution
– Food and industrial supplies
– Automotive parts

Any business working with multiple pick zones can benefit instantly.

Pick Pack and Pass vs Traditional Picking

PPP is built for growth and automation—traditional picking simply can’t keep up with high-volume environments.

Challenges Pick Pack and Pass SAP EWM Solves

– Slow picking due to long walking routes
– Errors caused by worker fatigue
– Warehouse congestion
– Difficulties scaling during promotions or seasonal peaks
– Multi-zone coordination issues
– High cost per order fulfilment

SAP EWM’s structured workflow eliminates most of these pain points.

Tips to Optimise Pick Pack and Pass in Your Warehouse

1. Maintain Clean Zone Layouts
Clutter slows passes and confuses staff.

2. Use Standardised Totes/HUs
Uniform handling units ensure faster movement.

3. Train Zone Specialists
Workers become fast experts on SKUs in their area.

4. Integrate Automation Where Possible
Conveyors, AMRs and pick-to-light reduce delays.

5. Monitor KPIs
Track pick rate, pass delays, error rates and cycle times.

Smart Tip

If your warehouse has multiple zones or high SKU diversity, PPP in pick pack and pass SAP EWM can dramatically reduce fulfilment time while increasing accuracy making it one of the most scalable, future-proof workflows available today.

Helpful External Resource (DoFollow)

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Internal Links (DoFollow)

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Clear Headline

SAP EWM Pick Pack and Pass Solutions That Boost Warehouse Speed and Accuracy

Subheading

A smarter, faster fulfilment method designed for multi-zone warehouses and high-volume distribution.

Location

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