Voice Picking: Transforming Supply Chains with 25% Productivity Gains and 99%+ Accuracy

Written by Lee Koutsos, Director Real Time Logistics (RTL), ANZ

In a global marketplace defined by rapid change and heightened competition, supply chain operators face relentless pressure to boost productivity while maintaining near-flawless accuracy. For many, voice picking solutions have become a strategic response to these challenges. By delivering spoken instructions through headsets, these systems allow warehouse workers to fulfill orders hands-free, offering tangible benefits in speed, precision, and flexibility. It’s no surprise that companies adopting voice picking technology often see productivity gains well above 25%, with accuracy rates that can exceed 99%. As consumer and B2B demands continue to grow, voice picking is increasingly acknowledged as a mission-critical tool for agile and efficient operations.

Advancing Voice Picking Technology

Voice picking technology in the warehouse isn’t new, in fact, its roots stretch back several decades. Early iterations featured bulky headsets, basic speech recognition, and limited integration with other warehouse systems. As hardware advanced, becoming lighter and more ergonomic, voice recognition software evolved to include more sophisticated algorithms, accommodating different accents and dialects. The availability of high-speed Wi-Fi and mobile computing also made it significantly easier to deploy voice solutions in various types of facilities, from large-scale distribution centres to smaller regional warehouses.

Initially viewed as a niche solution for major players, voice picking has now gained broader acceptance across diverse industries. Retailers, e-commerce operations, third-party logistics providers, and even smaller specialty warehouses rely on voice technology for tasks ranging from order picking and put-away to cycle counting and inventory replenishment. With workflows and facility sizes varying widely, the adaptability of voice solutions has been a key driver of their mainstream adoption.

Hands-Free, Eyes-Free Operations

One of the most compelling reasons to adopt voice picking is its hands-free, eyes-free nature. Operators wear a portable, belt-mounted voice terminal and a wireless headset. Workers can then follow spoken instructions via their headset, eliminating the need to constantly glance down at handheld scanners or paper pick lists. The voice terminal communicates wirelessly in real time with the host computer or Warehouse Management System (WMS), prompting the operator through each assignment, with verbal instructions.

After each task is completed, the operator confirms it aloud through the headset’s microphone. The voice system then verifies this confirmation and promptly issues the next instruction, creating a continuous, hands-free workflow. By providing these verbal prompts and requiring spoken confirmations, the technology helps eliminate common errors, such as scanning the wrong barcode or misreading a label. Modern voice systems often include adaptive learning capabilities that refine recognition over time, improving performance even in noisy environments or with diverse speech patterns.

These solutions also typically integrate with warehouse and labour management tools, boosting efficiency through real-time data that helps managers forecast labour, reallocate resources, and expedite order flow. Some operators pair voice with vision systems or augmented reality, combining audio and visual cues for tasks requiring extra precision. Meanwhile, the rise of IoT and robotics paves the way for seamless human-machine collaboration, bringing warehouses closer to fully data-driven operations.

Alongside these technical advancements, the benefits of voice picking solutions extend beyond accuracy improvements. Workers typically complete picks faster because they don’t have to pause for handheld devices or paperwork, and safety improves as they maintain a clearer line of sight and more natural posture while moving through the warehouse.

In high-volume facilities, where every second counts, reducing the risk of accidents and improving picking speed are equally vital. A hands-free approach also helps mitigate worker fatigue and often simplifies onboarding. New hires can be trained on voice solutions within an hour, cutting typical training times in half compared to handheld scanning or manual processes. This faster ramp-up is particularly beneficial in industries that rely on seasonal staff or face high turnover rates.

A Game-Changing Solution for Complex Environments

A primary example of voice picking’s potential comes from cold storage environments, where protective gear, low temperatures, and bulky gloves make traditional methods impractical. Leading cold storage and supply chain solutions provider Americold was the first in Australia and New Zealand to adopt voice technology when they partnered with Dematic in 2002. Since then, Americold has continuously upgraded its systems to stay competitive.

Voice picking technology eliminates the need for paper lists or handheld devices, helping operators maintain accuracy and speed even under demanding conditions. Workers receive clear, spoken instructions, and each pick is instantly recorded in the WMS, creating a paperless, data-driven environment that enhances decision-making and quickens response times.

In cold storage facilities, where manual precision is restricted, this hands-free approach can boost productivity by up to 35% compared to manual methods, largely by minimising pauses and unnecessary movements. Operators train the system to recognise their individual voice patterns within minutes, enabling both new and experienced employees to reach high efficiency quickly.

Recent upgrades to Americold’s voice picking solution have further improved scalability, flexibility, and overall visibility. Managers can optimise workflows, fine-tune resource allocation, and respond swiftly to changing customer demands. Americold’s sustained investment in voice technology highlights how these systems can thrive in even the most challenging environments, delivering tangible gains in productivity and safety.

Best Practices for Implementation

Realising the full potential of voice picking often involves more than a straightforward technology upgrade. It’s essential to assess existing workflows, identify bottlenecks, and define clear objectives for efficiency and accuracy gains. Companies that treat voice as a technology upgrade alone tend to see 5-10% productivity gains, while companies that utilise voice as part of a broader warehouse operations optimisation initiative typically experience a 25-35% increase in case picking productivity, and 45% or more in piece picking.

Choosing the right implementation partner can also be a deciding factor in a project’s success. For example, Dematic begins with a consultative approach to map out process flows, pinpoint operational challenges, and recommend the right blend of technologies for each facility. Dematic’s local software team in Australia focuses on delivering advanced yet tailored solutions for businesses, backed by ongoing 24/7 support. Providing comprehensive training, Dematic’s “Super-user” training sessions equip key staff with in-depth knowledge. This is also followed by a “Hypercare” phase at go-live, ensuring smooth adoption and immediate troubleshooting if needed.

Driving Future Innovation and Efficiency

As automation and data-driven processes reshape warehouse operations, voice picking continues to evolve. Advances in machine learning promise to improve speech recognition in noisy settings, while “cobotics” may pair humans and robots for collaborative efficiency. At the same time, IoT-based asset tracking and augmented reality can offer real-time alerts and visual cues, making workflows even more intuitive.

In modern warehouse operations, voice picking is now recognised as a critical enabler of accuracy, speed, and adaptability. By integrating seamlessly with broader warehouse management and automation strategies, it equips businesses to make data-informed decisions, optimise resources, and stay competitive in fast-changing markets.