Three ways to Mitigate Warehouse Picking Errors

Warehouse Picking errors can kill a brand’s effort to deliver customer delight. According to research by Aberdeen Group in 2022, 67% of customers consider the accuracy of an order as the top three factors that influence their satisfaction. What’s worse, 23% of customers are likely to switch to a competitor if they experience more than one fulfillment error.

Warehouse Picking errors can have a big impact, leading to extra costs for restocking inventory and reshipping goods. That’s why it’s so important to figure out what’s causing these errors and put effective solutions in place to keep things running smoothly. 

Root Causes of Warehouse Picking Errors

• Manual Picking Errors: One of the primary contributors to warehouse picking errors is manual picking errors such as selecting the wrong items contribute to 35% of picking mistakes, often stemming from staff misreading labels or selecting the wrong products.

• Inadequate Training: In a survey by the Material Handling Institute in 2022, 22% of warehouses experienced productivity losses due to untrained staff. Insufficient training on warehouse equipment and procedures can increase the likelihood of errors, as untrained personnel may struggle to perform tasks accurately.

• Poor Warehouse Organization: A disorganized warehouse can lead to a decrease of 20% in operational efficiency also causing confusion, making it difficult for employees to locate the correct items efficiently.

• Ineffective Inventory Tracking: Inaccurate inventory records can cause staff to select items that are out of stock, further exacerbating warehouse picking errors. 

ALSO READ: Automated Order Picking: A New Era of Efficiency

Strategies to Mitigate Picking Errors

To address these challenges, companies can adopt several strategies: 

• Comprehensive Employee Training: Investing in thorough training programs ensures that employees are well-versed in warehouse machinery, picking processes, and inventory management. Proper training can enhance productivity and reduce human error. A report from the Warehousing Education and Research Council (WERC) found that warehouses that invested in employee training saw a 30% reduction in picking errors and an 18% improvement in overall productivity (WERC, 2022). 

• Efficient Warehouse Organization: Organizing the warehouse effectively can streamline operations. Implementing efficient storage solutions, properly labeling products, and maintaining clear aisles can help staff locate items with ease. Research from the Institute of Supply Chain Management (ISM) shows that warehouses with optimized layouts experience up to 40% faster picking times, reducing the likelihood of errors and improving overall throughput (ISM, 2023). 

• Inventory Management Software: According to Gartner, companies that use advanced inventory management solutions experience a 20% increase in order accuracy and a 15% boost in operational efficiency. Utilizing advanced inventory management software allows for accurate tracking of stock levels, facilitating easier identification of available items. 

ALSO READ: 8 Strategies in Warehouse Order Picking

Embracing Innovative Technologies

To significantly reduce warehouse picking errors, businesses should consider integrating cutting-edge warehouse management systems (WMS): 

• Automated Picking Solutions: A study by Research and Markets estimates that robotic picking systems can reduce picking errors by up to 90%. Automated picking systems use robotics to retrieve items from shelves and transport them to packing areas. This technology enhances efficiency and minimizes human error, accelerating order fulfillment and boosting customer satisfaction. 

• Barcode Scanners and Mobile Devices: These tools improve inventory tracking accuracy, allowing staff to locate items more effectively. 

Addverb Technologies’ Solutions

Addverb Technologies offers innovative solutions to streamline picking processes: 

Goods-to-Person Solutions

Box-It,An advanced Goods to Person SKU Picking Solution, Box-It allows for the efficient and precise picking and delivery of various SKUs required for order consolidation. This process reduces time consumption by over 90% and significantly improves accuracy. 

Person-to-Goods Picking Technologies

Solutions such as pick-by-voice, pick-by-vision, and pick-by-light provide precise guidance to pickers, facilitating efficient order consolidation. 

• Pick-by-light: Rapido, our trusted Pick-to-Light solution empowers your workforce to pick the correct products and quantities swiftly and accurately for order fulfilment. With its unparalleled speed and operator-based approach, Rapido ensures efficient and precise order picking, making it the ultimate choice for rapid fulfilment. 

• Pick-by-voice: Zesty, our advanced Pick-by-Voice technology revolutionises the order-picking process. By eliminating the need for paper or RF devices, Zesty streamlines operations through voice commands. Experience quick and precise item picking and packing with real-time instructions delivered through an intuitive interface powered by cutting-edge speech recognition technology. 

Warehouse Control System

This system allows businesses to allocate tasks based on order priority, optimizing workforce efficiency. Recognizing the physical and emotional toll of repetitive tasks, we also offer AI-driven robotic picking solutions. These advanced systems utilize algorithms to accurately identify and pick products, featuring specialized grippers tailored to specific items. This alleviates staff from monotonous manual tasks, allowing them to focus on higher-value activities. 

Conclusion

In summary, warehouse picking errors can lead to significant operational challenges, including increased costs, lost revenue, and negative impacts on customer satisfaction and brand reputation. To combat these issues, companies must identify the underlying causes of warehouse picking errors and implement robust solutions, including advanced warehouse management systems, innovative technologies, best practices, and comprehensive employee training.

By doing so, businesses can enhance their warehouse operations, reduce warehouse picking error rates, and ultimately improve their bottom line. 

Founded in 2016, Addverb offers complete robotics solutions for warehouse and industrial automation, with a strong global presence through its subsidiaries worldwide. The company provides a range of in-house automation products, including Autonomous Mobile Robots, ASRS, and sorting technologies. It serves over 350+ clients, including well-known companies such as Coca-Cola, Amazon, and DHL.