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The Cherry Picker & The Position

Welcome back to Warehouse and Operations as a Career. I’m Marty, and today we’re talking about a piece of equipment that almost everyone in our industry recognizes, but not everyone fully understands it. If you’re a long time listener you’ll remember I spent about 6 years operating it on the 2nd shift, in the outbound operations within the food service distribution arena. We’re going to talk about the cherry picker today. Now its proper name, or if your ordering one from the manufacturer, it’ll be referred to as an order picker. This machine helped shape the modern warehouse, the newer e-commerce departments, and really, distribution as a whole. It’s increased productivity, allowed us to build higher racking, with many more selection slots, helping reduce the buildings footprint, reducing the cost of real-estate needed. But it’s also one of the most unforgiving pieces of equipment to operate. So today, I want to really walk through where the order picker came from, why it exists, what it’s good at, where and what it struggles with, how it’s used, and most importantly, the dangers, limitations, and responsibility that come with it. This isn’t just about the equipment. And I know I harp on it, but it’s about our mindset, maturity, and our career. And you ought to know, I’m going to take this opportunity to again stating that you should never get on or even touch a piece of equipment or machine that you have not been trained and certified to be on. Now that all that’s out of the way, let’s talk about the cherry picker! Believe it or not, the cherry picker didn’t start in a warehouse. Its earliest versions were used in agriculture, specifically for harvesting fruit. Farmers needed a way to lift workers safely into trees so they could hand-pick produce without ladders or unsafe climbing. The concept was simple, instead of bringing the fruit down, bring the worker up. As warehousing evolved, especially in the mid-20th century, that same idea became essential indoors. Warehouses started growing up instead of out. Land became expensive. Inventory counts increased. SKU or item counts exploded. Full pallets weren’t always the answer anymore. Traditional forklifts could move pallets just fine, but they couldn’t safely lift people to pick individual cases. And that’s where the order picker was born. By combining a powered industrial truck with an elevated operator platform, warehouses could store product higher, pick individual cases efficiently, reduce walking and ladder use, and dramatically increase picking productivity. Over time, these machines were refined with better controls, safety systems, harness requirements, and more stable designs. What we ended up with is one of the most productive, and demanding machines in the building. The defining feature of an order picker is simple but powerful, the operator rises or goes up in the air, up to the higher pick slots with the platform and forks, with a pallet usually. And that changed everything. Instead of pulling pallets down to floor level or relying on ladders and mezzanines, the operator works directly at the pick face or pick slot. Here’s why that matters. First, vertical access. Order pickers allow warehouses to fully utilize high-bay racking. Space that would otherwise be wasted becomes valuable inventory real estate. Second, case-level picking. This machine is built for piece and case selection, not full pallet movement. That makes it ideal for retail, grocery, and e-commerce operations where accuracy matters as much as or more than speed. Third, productivity and accuracy. A trained operator following a clean pick path can maintain a strong cases-per-hour average while reducing errors, with less walking, less searching for the product, less backtracking. And fourth, when used properly, reduced physical strain. The machine does the lifting, not the operator. No constant ladder climbing. No unsafe stretching to reach the product. And no carrying cases long distances. But, and this is a biggie, all of those benefits only exist when the equipment is used correctly and the warehouse is layed out and slotted properly. It needs to be said that order pickers are a specialized piece of equipment. They are not one-size-fits-all machines. They perform best in the high-bay warehouses, and narrow-aisle configurations. They require clean, dry, flat floors, and facilities with defined pick paths and in operations with high SKU and item counts. They are common in retail distribution centers, grocery warehouses and those large e-commerce fulfillment operations. They are not ideal for outdoor use, on uneven or damaged flooring, and up front in our dock areas or congested pedestrian zones and walkways. If your facility isn’t designed for elevated picking, an order picker becomes more risk than reward. Now we get to the part that separates training from experience. The order picker is one of the most dangerous pieces of equipment in the warehouse if m...