Pick, Pack and Pass in SAP EWM: Complete Process Guide

The Pick, Pack and Pass process in SAP EWM is a warehouse fulfillment method that enables efficient multi-zone picking, packaging, and handoff across activity areas within a warehouse. Rather than assigning a single warehouse worker to follow an entire order from start to finish, the Pick, Pack and Pass approach divides the warehouse into operational zones, allowing workers to specialize in their area and pass goods on to the next zone via conveyor belts or other transport systems. This significantly reduces travel time, improves throughput, and increases order accuracy in high-volume warehouse environments. According to Supply Chain Digital, zone-based picking strategies like Pick, Pack and Pass can improve warehouse picking efficiency by up to 30% in large distribution centers.

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What is Pick, Pack and Pass in SAP EWM?

Pick, Pack and Pass is a feature in SAP Extended Warehouse Management (SAP EWM) that allows you to manage product picking, packaging, and transportation through various activity areas in your warehouse. A conveyor belt, for example, can move goods from one operational area to another. An operation area can be compared to an aisle or picking zone, where a warehouse worker is responsible from an organizational standpoint. The warehouse worker passes on the goods as soon as they have completed the warehouse order in their area.

When you use this function, the system generates a higher-level warehouse order with the pick-HUs (Handling Units) for all warehouse tasks that need to be generated. The warehouse worker receives the warehouse order for their specific operation area, as well as the warehouse tasks associated with it. The system then coordinates the handoff to the next zone automatically.

As MDP Group, we have configured Pick, Pack and Pass processes in SAP EWM for clients in retail, pharmaceutical, and consumer goods industries. In our experience, the most critical success factor is correctly defining activity area boundaries and ensuring the conveyor belt integration is mapped accurately to the EWM warehouse structure.

How Warehouse Orders Work in Pick, Pack and Pass

In EWM, a warehouse order is a work package that a warehouse employee must complete within a certain time window. A warehouse order may include warehouse tasks from one or more deliveries — putaway, picking, packing, and so on. SAP EWM maximizes the sequence of work that needs to be completed in a time slot through this approach. This is done on a task-by-task basis within each zone, rather than following an entire distribution or customer order from start to finish.

The Pick, Pack and Pass process works as follows:

Pick: Warehouse workers in designated picking zones select items from storage bins according to their warehouse orders.
Pack: Items are consolidated and packed in designated packing stations, where system-guided packing instructions ensure correct packaging materials and quantities.
Pass: Packed goods are transferred — via conveyor, forklift, or other transport — to the next activity area (e.g., quality check, shipping staging, or another picking zone).

For related wave and outbound order management in SAP EWM, our guide on SAP EWM Wave Management and picking optimization covers how waves coordinate outbound processes.

What Does Pick, Pack and Pass Provide?

Different SKUs can be strategically organized based on their characteristics, including weight and volume handling methods, temperature zones, and sales velocity. Warehouse staff can specialize in and better manage a specific type of SKU, improving accuracy and speed. This approach removes the need for further consolidation at a central packing station, since packaging happens at the zone level. Key benefits include:

Reduced travel time: Workers stay in their zone; goods travel via conveyor rather than workers walking across the warehouse.
Higher throughput: Multiple zones work in parallel, significantly increasing order processing speed.
Improved accuracy: Zone-specific training reduces errors; system-guided tasks minimize mis-picks.
Scalability: Additional zones can be added as warehouse volumes grow without restructuring the entire picking process.
Better ergonomics: Workers specialize in products suited to their physical capabilities (e.g., heavy items in separate zones).

Frequently Asked Questions (FAQ)

What is the difference between Pick, Pack and Pass and normal picking in SAP EWM?

In normal SAP EWM picking, a single warehouse worker may be responsible for picking items across multiple zones for one order, resulting in long travel paths. Pick, Pack and Pass divides the warehouse into activity areas; each worker specializes in their zone and passes goods to the next area via a transport system. The system coordinates multi-zone orders automatically, generating zone-specific warehouse orders that are linked to a parent-level handling unit. This approach is most beneficial in large warehouses with high order volumes and diverse SKU profiles.

Does Pick, Pack and Pass in SAP EWM require conveyor belt hardware?

No. While conveyor belts are the most common transport method used with Pick, Pack and Pass, the process can also be implemented with forklifts, carts, or manual transfer between zones. SAP EWM models the handoff as a transport unit transfer between activity areas, regardless of the physical transport method. The configuration defines the sequence of activity areas and the system handles the task routing; the physical transport method is a warehouse design decision independent of the EWM configuration.

Can Pick, Pack and Pass work with RF or mobile devices in SAP EWM?

Yes. SAP EWM fully supports Pick, Pack and Pass execution via RF (Radio Frequency) scanning devices and mobile devices. Workers in each zone confirm their warehouse tasks using handheld scanners, and the system automatically triggers the next step in the Pick, Pack and Pass sequence. With SAP EWM's newer Fiori-based mobile interface, the process can also be managed via tablets, providing a more intuitive experience for warehouse staff.

Conclusion

The Pick, Pack and Pass process in SAP EWM is a powerful tool for high-volume warehouses looking to improve throughput, reduce travel time, and increase order accuracy. MDP Group provides expert SAP EWM consultancy to help you design and implement the optimal picking strategy for your warehouse operations.