How do you ensure order accuracy?

Barcode scanning is only one way in a long list of things that can make your warehouse more efficient and productive. Logical layout, identifying fast moving lines and locating their pick faces closer to despatch staging lanes helps to speed up order picking. Having replenishment stock above its dedicated pick face also aids more efficient movement and decreases the risk of damaged stock in transit from storage location to pick face and also helps order picking accuracy. There will always be the risk of human error but it can be minimised or eliminated by paying attention to detail and effective ongoing trainin

Barcode scanning works, but if your employees don't understand the product they are looking for, it creates chaos. By making sure your team understands where things should be, by having similar items grouped with each other, and having clear, labeled shelves, that's what works.

Barcoding and other supporting tools and approach can make your picking efficient. However before implementing the tools the companies should invest in the warehouse work force. Having the right work force with a mindset that value the importance customer satisfaction and shelf availability. Companies should be able to cascade the importance of having accurate order picking on - Revenue - Cost - Customer Satisfaction - Shelf availability - Cash-to-Cash cycle Once all that is communicated to the warehouse staff then using technology such as the barcode will drive great results

Scanning is certainly better than paper based systems in the most part however it does have its drawbacks. Staff training is important and other technologies such as voice, vision and rfid are as effective if not better. The move to goods to person systems with pick and put to light technology with photographs of the product are very effective.

Using barcode scanning is as effective as the people that use it. One mistake we make is to implement a new system without providing enough training on how to exploit the benefits of the tool. To take full advantage of any system, we need to have the proper training in place, and simply promote the reward of increasing knowledge, applying knowledge and sharing knowledge. Bar Scanning is a great method, as long as we take full advantage of the whole system to help us with inventory management. To have what we need, when we need it is the key, and the barcode system can provide a faster response.

The quality check should be embedded within the picking process itself on two levels 1- system 2- on picking On system - While the system should not allow the allocation of stocks that expired or near expire - system will be designed to allocate only from salebels locations On Picking - As part of the process the picker should be trained to avoid defects - Picker should also conduct a QC check upon picking * Then Double check after picking on SKU, batch, expiry date, Qty * Then the final check will be upon loading which is supposed to be a check based on Qty of shipping units

Implement quality control: Execute a quality control process that includes a secondary check by another staff member, especially for large orders.

In addition to quality of the product, quality of the process needs to be ensured as well. One of common method is to conduct periodic stock count and cycle count. High level of process quality will have direct impact to overall accuracy of the warehouse operation, order processing, activity status and reports.

Training is mandated for all warehouse processes, however, in my opinion developing a culture of - Accountability - Dependability - Responsibility - Quality Are the winner's attitude which can lead to accurate orders, Lacking these attitudes will always be a source of issues within your operation.

In short, training, empowering, responsibility and than accountability is the right approach.All these steps should be followed in sequence.

Consistency at all levels is key. The SOPs need to be simple and become the bible off operations. Keeping the teams, involved, informed and educated leads to successful performers/performance. #Peopleprocess=success

Order Accuracy ; only could be achieved with the Person self efficiency ( this continue until the person is engaged so not advisable ) ; So the left is only Technology; In the Technology one should only ensure that each Timeline Notifications is must; this way the team in the System will work perfectly. Rest is the common part what we do ....

Optimizing your warehouse layout is crucial for both current and future order accuracy. A well-organized layout reduces travel time, enhances visibility, and boosts productivity. To achieve this, consider factors like warehouse size, product types, order patterns, and operational flow. Techniques like slotting and zoning not only optimize current operations but also prepare your warehouse for future growth and efficiency.

Many tend to organize the warehouse by grouping similar products, however, having similar products side by side is a common cause of picking mistakes. It's better to group SKUs by their likeliness to be picked in the same order, and if they are similar, to have a clear visual way to identify them (like color coding, different bins, etc.) For small SKUs we can consider automation (vertical or horizontal carrousel) which optimizes storage space and can prevent picking mistakes by automating the process.

One thing I have found helpful, is cosidering an area in a Warehouse layout for dispatching. Loading bays are essential for segregation of planned Finished Products for dispatching and the Warehouse stock. In this area the Warehouse staff can check the orders in some aspects such as quantity, packaging quality, loading sequence, etc.

In a bustling warehouse near the city, a team was on a mission: perfecting orders for delighted customers. Their secret? An advanced computer system, barcodes, and a skilled crew to ensure orders were spotless. They embraced surprise inspections, followed clear procedures, and learned from every mistake. Their technology streamlined operations, and they maintained strong supplier relationships. Customer feedback was their guiding star, making each day an adventure in perfecting order accuracy.

You can use tools such as key performance indicators (KPIs), audits, or surveys to measure and monitor your order accuracy rate, identify the root causes of errors, and implement corrective action

Conduct regular audits: Regularly audit your inventory and order management processes to identify any areas that need improvement or staff training.

One thing I have experienced is that picked stock is not always effectively staged to be checked. Stock mixups in the staging and checking area leads to time wasted looking for the correct stock per load and ultimately wrong stock getting loaded on wrong loads. One can have the best systems and processes, however if the staff does not have a clear understanding of the importance of marking and staging stock correctly, one will always struggle with inaccuracies and turnaround times.

Lastly which you can measure you cannot manage. Setting the right KPI is always crucial. One great KPI that can be used is OTIF On-time-In-Full. Setting clear SLA and order-placing cutoff time will help you manage your resources on the right workload. Do not overload your resources, especially the workforce.

In most cases, if we can focus deeply on improving and maintaining high operational standards in the 3 most important areas - people, process and systems, achieving high or even perfect accuracies in order fulfilment or inventory management is a logical outcome of any effective operational management strategy. Using bar code is a proven, cost effective method via system, but equally important are good processes, and competently trained people.

Standard Operating Procedures (SOPs): Create and document standard operating procedures for order processing. This helps ensure consistency and minimizes errors