Picking full, unopened cases from pallet inventory to fill orders, a common pick type in distribution centers that ship case quantities to stores or customers.
Detailed Definition
Full case pick means the order quantity is filled in whole cases rather than whole pallets or single units. A picker, often on a pallet jack or order picker, travels to a pick face, takes the required number of cases and builds them onto an outbound pallet. It sits between full pallet pick and split case pick in the usual order profile. Store replenishment orders in grocery and retail distribution are frequently case picked.
How a full case pick operation is laid out
Case pick faces are usually on the floor level or the first beam level of selective rack, or in carton or pallet flow lanes, so pickers can reach cases without a lift. Reserve pallets of the same SKU sit above and are brought down as full pallet moves when the pick face runs low. Fast movers are typically slotted closest to the dock and at waist height to cut travel and bending.
Pickers often build mixed-SKU outbound pallets, which makes the build sequence important: heavy, sturdy cases go on the bottom and crushable items on top.
What to check on the outbound pallet
- The base pallet matches the customer's footprint and type, often 48 x 40 in.
- Cases are stacked inside the pallet edges with no overhang.
- The load is stable and wrapped before it leaves the pick zone.
- Each pallet carries the shipping label the receiver expects, such as a GS1-128 label with an SSCC.
A common mistake is treating the outbound pallet as an afterthought. A broken or undersized base pallet can cause a mixed load to lean or collapse in transit, and some receivers reject loads that do not match their pallet or labeling rules.
Related Glossary Terms
Frequently Asked Questions
What is the difference between full case pick and split case pick?
Full case pick ships whole, sealed cases exactly as they arrived from the manufacturer. Split case pick, also called piece or each picking, opens cases and picks individual units or inner packs into totes or cartons. Split case picking is more labor intensive per unit and usually needs different storage such as shelving or carton flow, while full case picking works from pallet positions and builds outbound pallets.
What equipment is used for full case picking?
Low-level case picking is commonly done with electric pallet jacks or rider pallet trucks that carry one or two outbound pallets while the picker walks the aisle. When pick faces are on upper rack levels, operators use order pickers that raise the operator with the load. Some facilities add conveyors, voice picking or pick-to-light systems. Operators of powered trucks must be trained under OSHA 29 CFR 1910.178.