In distribution—especially for building materials, HVAC, or other inventory-intensive businesses—order picking and staging is where promises become deliveries. If your ERP workflows in this area aren’t dialed in, you risk slow order fulfillment, costly errors, and frustrated customers.
Here are the top 10 things you need to know to optimize your ERP’s picking and staging workflows:
- ERP Workflows Can (and Should) Match Your Physical Process
Too many companies try to adapt their warehouse process to fit the ERP. Instead, your ERP should be configured to match the real flow of people, materials, and trucks. Map it out first—then build it into the system.
- Location-Level Visibility is a Must
You can’t pick efficiently if your team doesn’t know where the product is. Your ERP should track inventory down to specific yard zones, bins, shelves, or staging areas—not just by warehouse name.
- Batch Picking, Wave Picking, or Single-Order Picking—Choose Wisely
Different picking strategies work for different businesses. Your ERP should allow you to configure:
Batch picking (grouping similar orders)
Wave picking (picking by route or schedule)
Single-order picking (for custom or rush orders)
Pick the right method for your team size, order volume, and layout.
- Staging Zones Need to Be Built Into the ERP
Staging is the final checkpoint before loading—and your ERP should treat it that way. Use custom workflows to:
Assign staging zones by order or route
Track items once picked but not yet shipped
Alert teams to staging delays or issues
This reduces misloads, lost pallets, and last-minute scrambles.
- Barcoding and Mobile Scanning Make It 10x More Accurate
Integrate barcode scanning directly with your ERP to confirm every pick and move. Whether it’s for individual products or entire pallets, scanning helps:
Eliminate manual errors
Confirm correct quantities and locations
Speed up staging and loading
Your ERP should log every scan in real time.
- Picking Should Trigger Inventory Updates—Automatically
Don’t wait for shipping to update inventory. As soon as items are picked, your ERP should:
Adjust available quantities
Flag low stock if thresholds are hit
Hold stock from being promised to another order
This keeps your system accurate, even in fast-paced environments.
- Delivery Routing and Staging Go Hand-in-Hand
For many distributors, especially those delivering to job sites, the order of staging matters. Your ERP should support:
Route-based staging (so loads match drop-off order)
Load sheets for drivers
Mobile checklists or confirmations for dispatch teams
It’s not just about picking the right stuff—it’s about picking it in the right order.
- Exceptions and Substitutions Need a Built-In Workflow
Backorders, out-of-stock items, or substitutions shouldn’t derail your process. Your ERP should have logic for:
Flagging missing items at pick time
Suggesting approved substitutions
Automatically notifying sales or customer service
This keeps operations moving while keeping the customer in the loop.
- Reporting Helps Identify Bottlenecks
Your ERP should track how long each step of the picking and staging process takes. Use this data to:
Spot slow zones or inefficient layouts
Improve shift planning or team assignments
Set KPIs like picks per hour or staging accuracy rates
- You Can Start Simple and Scale Up
If your current ERP workflows are paper-based or semi-manual, don’t worry. Start with simple automation—like mobile pick lists or staging alerts—and build from there. The key is to make sure the foundation is solid and flexible.
Final Thought
Order picking and staging isn’t just a back-end process—it’s the last stop before the customer experience begins. When your ERP workflows are built with that in mind, you’ll deliver faster, make fewer mistakes, and build more trust with your clients.
