Have you thought of creating a UDF in the Item Warehouse table to hold that data and then adding the UDF to the picking sheet works table.

To be truthful no, I'll have to look into it. Not sure how it would compare the Item code row and bin to the next item row and bin.

I think I may create a excel database and add it to a Crystal report to test it. I may be overthinking it. I may only need the first column in my table that compares everything to row 1 and just sort it by the lowest number.

If we have Bin numbers setup already in the Item Warehouse, could you sort the picking sheet by that field and if you can will the comment field tied to that line follow it?  I have the comment field in Details a above details b in group header#1

Both Scanco and ScanForce have solutions for this, which also include scanners.
What if you want to pick five separate orders simultaneously? 

The pullers are only supposed to pull one order at a time. I think if that pick up a few small orders they scan them separately at the end.

I was over thinking it. I just created a test excel order and one for distance and it sorted it just right. I didnt need to worry about what the next item was on the order and compare the distance depending on where that item was. I only needed one column of data that compare the distance to row one and then sort it by distance.

It appears that sorting something in the picking sheet is not that easy. I've made a custom formula field that I want to sort by but I dont know how. There is a bunch going on in the picking sheet that I dont want to break.