Picking errors are common in warehouse operations, especially as businesses grow and their inventory becomes more complex. Mistakes like selecting the wrong product, incorrect quantities, or mislabelled items can pose significant challenges for warehouse managers and eCommerce businesses. Industry statistics reveal that over 35% of warehouses have a picking error rate of at least 1% or more. These errors increase operational costs, cause shipping delays, and ultimately lead to poor customer satisfaction. Even a small error can have far-reaching consequences for businesses reliant on efficient warehouse management.

Over time, picking mistakes can add up, resulting in lost revenue, increased returns, and damage to a company's reputation. A single error might seem minor, but when multiplied across hundreds or thousands of orders, the impact becomes substantial, affecting profitability and customer trust.

In this article, we’ll explore 7 practical strategies for reducing picking errors and for overall picking accuracy improvement in your warehouse. By following these steps, businesses can enhance efficiency, reduce costs, and maintain a high standard of customer service.

1. Implement and Review Standard Operating Procedures (SOPs)

Clear, well-defined Standard Operating Procedures (SOPs) are essential for reducing picking errors in any warehouse environment. SOPs provide consistency by standardising how tasks, such as picking and packing, are performed, ensuring that every team member follows the same steps. This helps prevent warehouse picking mistakes and streamlines operations, reducing the chances of human error.

A typical picking process SOP might include verifying product SKUs, using checklists, and double-checking orders before packing. For instance, when picking an item, the worker could cross-reference the product SKU with the order details to ensure accuracy. After selecting items, a checklist can be used to confirm that the correct quantities and products have been picked. Double-checking orders before packing is a particularly effective method to ensure that the picked items match the order, significantly reducing picking errors.

As the warehouse grows or new technologies are introduced, reviewing and updating these procedures regularly is vital. Outdated processes can lead to inefficiencies or warehouse picking mistakes, especially as the business scales. Regularly assessing and refining SOPs ensures that they remain relevant and effective.

Finally, these SOPs must be communicated clearly to all team members and are easily accessible. A structured SOP is only useful if everyone understands and follows it. Making SOPs available throughout the warehouse and ensuring that staff receive regular training can improve picking accuracy and ensure a smooth workflow.

2. Leverage Barcode Scanning and Automation

Barcode scanning is one of the most effective tools for reducing picking errors in warehouse operations. By automating the item verification process, barcodes provide an additional layer of accuracy, removing the reliance on human memory or visual identification, which can often lead to warehouse picking mistakes. Instead of manually matching items to an order, workers can scan barcodes to instantly verify that the correct product is being picked, ensuring higher accuracy.

Integrating barcode scanners with a Warehouse Management System (WMS), such as StoreFeeder, further enhances this process by providing real-time inventory updates. When an item is picked and scanned, the system automatically adjusts stock levels, preventing discrepancies between orders and available inventory. This level of automation ensures that businesses always have an accurate view of their stock, reducing errors and improving warehouse efficiency.

One of the key benefits of using barcode scanning is that it cross-checks items against picking lists, ensuring the right product is selected every time. For example, handheld scanners can be used to scan items as they are picked, with each scan verified against the order in the WMS. This minimises the likelihood of human error, as the system instantly alerts workers if the wrong item is scanned.

Another advantage is that inventory levels are updated automatically when items are scanned. This reduces the chances of stock discrepancies and eliminates the need for manual stock adjustments, which are prone to error. By streamlining this process, barcode scanning ensures that the correct items are picked, and inventory data remains accurate.

3. Introduce a Quality Control (QC) Process

Implementing a Quality Control process adds a crucial layer of accuracy to warehouse operations, ensuring that any errors made during the picking process are identified and corrected before orders are dispatched. By introducing a QC checkpoint, businesses can significantly reduce warehouse picking mistakes and enhance customer satisfaction. Whether the errors involve incorrect items, missing products, or incorrect quantities, the QC process serves as the final line of defence.

There are various ways to implement a QC process. One common method is manual double-checking, where a second team member reviews picked orders to confirm that the correct items have been selected. Another option is automating the QC process using a WMS, which can flag discrepancies between what has been picked and what was ordered. This speeds up the verification process and reduces the chances of human error.

For example, businesses can establish a designated QC team responsible for reviewing all picked orders before they are packed and shipped. This team can manually verify that the correct products and quantities have been selected.

Additionally, by using a WMS to reduce picking errors, the system can automatically alert staff if there is a mismatch between the items picked and the order details, allowing for corrections before the order is dispatched.

A dedicated QC team or an automated system helps catch errors like missing items or incorrect quantities before they reach the customer, reducing the need for costly returns and exchanges. This proactive approach leads to picking accuracy improvement and helps maintain a high standard of warehouse efficiency, ensuring that orders are fulfilled correctly the first time.

4. Optimise Warehouse Layout and Picking Routes

Optimising your warehouse layout is key to reducing warehouse picking mistakes and improving overall warehouse efficiency. By strategically organising items within the warehouse, businesses can minimise confusion during the picking process and reduce the likelihood of mistakes.

One effective approach is to implement logical item placement, where products are stored in a manner that reflects their type or order frequency. For instance, fast-moving items can be placed near the packing area to cut down on travel time and ensure that frequently ordered products are picked up quickly and accurately.

Clear signage and labels are equally important in maintaining an organised layout. Labelling aisles, shelves, and storage zones helps workers quickly locate items, reducing the risk of warehouse picking mistakes caused by confusion or misidentification. Organising the warehouse into zones based on product type, size, or popularity can also streamline the picking process, allowing workers to focus on specific areas and avoid unnecessary movement.

In addition to physical organisation, using a WMS can further optimise picking routes. A WMS can dynamically guide workers through the most efficient paths to complete tasks, adjusting routes based on order complexity or item location. This level of automation ensures that workers spend less time searching for items and more time fulfilling orders accurately. The system can even prioritise orders that contain multiple fast-moving items, helping workers move through the warehouse in a logical, efficient sequence.

For example, combining a well-organised layout with optimised routes generated by a WMS to reduce picking errors can significantly reduce unnecessary movement. By guiding workers through the warehouse efficiently, the system helps minimise confusion and ensures that orders are picked more accurately.

5. Regular Staff Training and Development

Regular training is critical for maintaining high standards in warehouse operations, particularly when it comes to reducing picking errors. Well-trained staff are better equipped to follow SOPs, use technology effectively, and adapt to new systems, such as barcode scanners and WMS. Continuous training ensures that employees are familiar with these tools and stay updated on the latest best practices in warehouse management.

Training sessions should focus on key areas like the correct use of barcode scanners, the importance of double-checking orders, and how to effectively utilise a WMS to reduce picking errors. By ensuring that staff understand and follow established procedures, businesses can significantly improve picking accuracy and minimise mistakes that can lead to costly errors or customer dissatisfaction.

For example, monthly refresher courses allow team members to stay aligned with updated SOPs and technology advancements. These sessions reinforce the importance of following procedures and provide opportunities to address any challenges or areas of confusion. Offering incentives to teams that achieve high picking accuracy improvement can also be an effective way to encourage adherence to best practices and boost overall performance.

One practical example is regular training on how to use a WMS. As staff become more familiar with the system, they will make fewer picking mistakes and work more efficiently, improving accuracy and warehouse productivity. By investing in continuous staff development, businesses ensure that their team always operates at its best, reducing errors and improving warehouse efficiency across the board.

6. Use a Warehouse Management System (WMS)

A warehouse management system, like StoreFeeder, is crucial in preventing picking errors by automating key warehouse processes. By reducing the reliance on manual tasks, a WMS helps minimise the risk of human error throughout the picking and packing process. From automating order verification to providing real-time inventory tracking, a WMS ensures that stock is accurately managed and orders are fulfilled correctly.

One of the primary features of a WMS that contributes to reducing picking errors is the automated generation of pick lists. These pick lists guide workers through the correct order and route, ensuring that items are picked efficiently and accurately. With integrated barcode scanning, the WMS provides a second layer of verification, allowing workers to scan items as they are picked, ensuring they match the order details. This double-checking process drastically reduces the likelihood of warehouse picking mistakes.

Additionally, real-time stock updates are another powerful feature of a WMS. As items are picked and scanned, the system automatically adjusts inventory levels, preventing issues like stockouts or overpicking. This real-time data helps ensure that pickers always have an accurate view of inventory, reducing the chances of errors related to unavailable stock or incorrect quantities.

For example, StoreFeeder’s WMS can update stock levels in real-time as items are scanned and picked. This level of automation improves picking accuracy and boosts overall warehouse efficiency by streamlining the entire order fulfilment process.

7. Conduct Regular Audits and Performance Monitoring

Conducting regular audits and monitoring warehouse performance are essential steps in maintaining high levels of accuracy and reducing picking errors. Audits can uncover recurring issues in the picking process, while performance monitoring highlights inefficiencies and areas for improvement. Both practices allow warehouse managers to proactively address challenges before they escalate into larger problems.

A WMS plays a vital role in tracking key performance indicators (KPIs) such as order accuracy rates, stock levels, and picking efficiency. By providing real-time data, the WMS allows managers to gain insights into the root causes of warehouse picking mistakes and make informed decisions to improve operations.

For example, monitoring order accuracy rates can reveal patterns of errors in specific zones or teams, enabling corrective measures to be taken.

Scheduling regular audits—whether weekly or monthly—of warehouse operations helps identify trends in picking errors. These audits provide valuable information about where mistakes are occurring, whether due to human error, workflow inefficiencies, or outdated processes. Armed with this data, managers can adjust training, revise SOPs, or reorganise warehouse layouts to improve accuracy.

The performance data gathered from a WMS can also be used to pinpoint inefficiencies and optimise operations. For example, tracking the performance of individual team members or shifts can reveal bottlenecks in the picking process, allowing managers to make targeted adjustments.

Conclusion

Reducing picking errors in a warehouse requires a multifaceted approach that includes clearly structured SOPs, regular staff training, automation technologies like barcode scanning, and continuous performance monitoring. Each of these strategies plays a crucial role in ensuring improvement in picking accuracy and maintaining high standards of warehouse efficiency. Regular audits and performance reviews further help identify recurring issues and make necessary adjustments.

A WMS, such as StoreFeeder, can be instrumental in automating error-prone tasks like generating pick lists, updating stock levels, and verifying order accuracy through real-time data. By integrating a WMS, businesses can streamline their operations, reduce human error, and optimise their picking processes for accuracy and efficiency.

Now is the time to assess your current warehouse processes and identify where improvements can be made. Consider adopting a WMS to reduce picking errors and elevate your warehouse operations to the next level, ensuring your business runs smoothly and customers remain satisfied.