Picking individual items from a case rather than full case, requiring smaller-package handling.
Detailed Definition
Split case picking, also called each picking or piece picking, means opening a case and picking individual units to fill an order, instead of shipping full cases or full pallets. It is typical in e-commerce, pharmacy, parts distribution and store replenishment. Because each order line involves small quantities, it is usually the most labor-intensive pick type, and it is often done from shelving, carton flow rack or automated goods-to-person systems, with picked units packed into totes or cartons before shipping.
Where split case fits among pick types
Warehouses usually recognize three picking levels. Full-pallet picking moves an entire pallet to the dock. Full-case picking takes whole cartons, often from pallet positions on the floor level of the rack. Split case picking takes individual units out of opened cases. Many orders mix all three, so facilities often separate them into different zones with equipment suited to each.
Replenishing split case pick faces
Split case pick locations are small and run out often. They are usually fed from reserve pallets stored in rack above or in a separate area, with replenishment triggered by minimum levels or by upcoming order volume. If replenishment falls behind, pickers find empty slots and orders are short. Good slotting keeps the fastest units closest to the pickers and sizes each location to hold at least a typical day's demand.
Accuracy, packing and the pallet
Picking single units raises the risk of wrong item or wrong quantity, so many operations scan each unit or use pick-to-light or voice systems. Picked units go into totes or shipping cartons, which may then be sorted and built onto pallets for store delivery. Mixed cartons and pallets need clear labels so the receiver knows what is inside.
Related Glossary Terms
Frequently Asked Questions
Why does split case picking cost more per unit?
Each pick moves only one or a few units, but the picker still has to travel, find the location, identify the item and confirm it. That fixed effort is spread over far fewer units than in case or pallet picking. Opening cases, handling loose units, packing and checking add more labor. Operations reduce the cost through good slotting, batch or zone picking, and automation where volumes justify it.
Is split case picking the same as each picking?
In practice, yes. Split case picking, each picking, piece picking and broken case picking all describe taking individual sellable units rather than full cases. Some operations use the terms slightly differently, for example using inner-pack picking for taking sealed inner packs out of a master case. When comparing systems or quotes, confirm what unit of measure is being picked and counted.