In distribution-heavy industries like building materials, the way your ERP system handles order picking and staging directly affects delivery speed, labor efficiency, and customer satisfaction. But not all ERP workflows are created equal—some are optimized for high-volume operations, while others focus on flexibility or ease of use.
If you’re evaluating ERP systems (or looking to improve your current setup), here’s a breakdown of how different ERP workflows stack up in real-world order picking and staging scenarios.
- Basic (Manual) ERP Workflow
How it works:
Orders are printed or viewed on-screen; warehouse staff manually locate items and mark them as picked.
Pros:
Easy to implement
Minimal training needed
Low initial cost
Cons:
Prone to human error
No real-time inventory updates
No tracking of pick accuracy or efficiency
Difficult to scale for larger operations
Best for:
Small warehouses with limited SKUs and low order volume.
- Guided Picking with Digital Pick Lists
How it works:
ERP generates optimized digital pick lists based on warehouse zones, order priority, or delivery routes. Staff follow step-by-step instructions on a handheld device or tablet.
Pros:
Faster and more accurate than manual picking
Reduces time spent searching for items
Can prioritize urgent orders or job site deliveries
Easier onboarding for new staff
Cons:
Requires mobile hardware and some user training
May need configuration for complex layouts
Best for:
Mid-sized suppliers with growing volume and multiple pickers.
- Barcode-Driven Picking and Staging
How it works:
Warehouse workers scan barcodes on items and locations to confirm picks and update ERP in real time. Items are staged in designated zones for consolidation, delivery, or will-call pickup.
Pros:
Real-time inventory accuracy
Strong reduction in picking errors
Full traceability by item, location, and staff member
Efficient staging for delivery runs or contractor pickups
Cons:
Requires barcode labeling and scanning infrastructure
Higher upfront cost and training investment
Dependent on Wi-Fi/network reliability
Best for:
Distribution centers and suppliers with large SKU counts, multiple warehouses, or frequent order changes.
- Wave and Batch Picking Workflows
How it works:
ERP groups orders by zone, product, or route for bulk picking. Items are later staged and sorted for specific orders.
Pros:
High efficiency for bulk picking
Cuts down on warehouse travel time
Works well with automated staging and delivery scheduling
Ideal for high-volume or time-sensitive fulfillment
Cons:
More complex to set up and manage
Requires disciplined warehouse layout and staff coordination
Not suitable for one-off or highly customized orders
Best for:
High-volume operations, regional hubs, or centralized distribution centers.
- Integrated Picking with Delivery and Job Site Coordination
How it works:
ERP picks orders based on delivery schedules, customer location, or job site readiness. Staging areas are aligned with truck loading zones or time windows.
Pros:
Tight coordination between picking, staging, and logistics
Reduces delays and partial deliveries
Improves contractor satisfaction with reliable timing
Enhances truck utilization and route planning
Cons:
Requires ERP integration with logistics/delivery modules
Complexity increases with job site variables or last-minute changes
Best for:
Construction-focused distributors, concrete or lumber suppliers, and any business tied to job site deliveries.
Final Thoughts: Choosing the Right Workflow
There’s no one-size-fits-all solution. The “best” ERP workflow for picking and staging depends on:
Your order volume and SKU complexity
Warehouse size and layout
Delivery scheduling and job site dependencies
Staff skill levels and turnover
Budget for hardware and training
Start by analyzing your current bottlenecks—then match your needs to the ERP workflow that can solve them, scale with you, and deliver measurable efficiency.
