Warehouse Picking Errors & How To Solve Them

Do you know how accurate your customer’s warehouse picking operation is? In an ideal warehouse, every order is picked and packed correctly and sent to the customer with a happy result. But we know it is not always that straightforward in the real world. Picking errors can occur for many reasons, but it is crucial that you, with your knowledge and expertise, fully understand some of the more common picking errors to help prevent them from happening in your client’s warehouse.

Inefficient Picking Routes

One of the most frequent challenges in warehouse operations is inefficient picking routes. Poorly designed layouts can lead to workers walking unnecessarily long distances, wasting time and decreasing productivity. This issue can become particularly costly during peak seasons when every minute counts.

Solution:

The key to solving this problem lies in warehouse layout optimisation. By strategically planning your picking routes and using slotting optimisation techniques, you can place high-demand or frequently picked items closer to the packing area. Additionally, integrating a Warehouse Management System (WMS) that uses real-time data and algorithms to suggest the most efficient picking paths can significantly reduce picking time and walking distance. These systems streamline operations, ensuring workers spend less time searching for items and more time fulfilling orders, improving overall efficiency.

Human Error in Picking and Packing

Human error is another significant challenge in warehouse operations, particularly in the picking and packing process. Picking the wrong item or packing incorrect quantities frustrates customers and costs warehouses, leading to returns, lost time, and reduced customer satisfaction.

Solution:

One of the best ways to reduce errors is to introduce structured storage systems with clear and defined sections for organised inventory. At QTS, our Warehouse Pick Bays provide precisely that. With items neatly divided into logical, named, and accessible zones, workers can quickly find the correct product without confusion. By clearly organising stock and ensuring it’s easy to navigate, the risk of errors is significantly reduced. This leads to more accurate orders, fewer returns, and a more efficient overall process.

Space Utilisation and Organisation

Another common issue that many warehouses need to address is better space utilisation. Cluttered aisles and disorganised stock make it difficult for workers to locate and pick items efficiently, while overcrowded areas can also create safety hazards.

Solution:

Optimising space is crucial not only for efficiency but also for maintaining safety standards. Products like our Underslung Loop Dividers and Hoop Dividers allow you to store long items vertically, freeing up valuable floor space. These dividers are perfect for storing bulky items such as timber or pipes, ensuring that your warehouse space is utilised to its full potential. The addition of a positioning plate also helps operators quickly and easily locate items, improving the overall picking process.

You can rely on our range of standard, framed, or hanging dividers to store larger boxes or palletised goods. These products help ensure that inventory is clearly segmented, preventing contamination or misplaced items and making order picking more efficient. By using these dividers, you can create a well-organised system where every inch of space is maximised.

Damaged Goods and Racking Systems

Warehouses are busy environments, and accidents can happen due to the constant movement of forklifts and material-handling equipment. Unfortunately, these incidents often damage racking systems, affecting inventory and disrupting the organisation.

Solution:

Preventing damage is crucial in maintaining both safety and operational efficiency. Our End-of-Aisle Rack Protectors and Pallet Racking Upright Protectors are designed to protect your racking systems robustly. These products shield your racks from potential impacts caused by forklifts or other handling equipment, reducing the risk of costly damage and ensuring your warehouse remains safe and functional. By investing in these protective measures, you preserve the integrity of your racking, minimise downtime, and ensure smooth, uninterrupted operations.

Inadequate Packing Stations

Packing stations are often overlooked in warehouse operations, but poorly organised or under-equipped stations can become significant bottlenecks. With sufficient space and proper organisation, the packing process can continue without delaying shipments or affecting customer satisfaction.

Solution:

A well-organised packing station is essential for keeping operations flowing smoothly. Our Wire Mesh Pallet Cages provide an excellent solution for organising items before they reach the packing station. These stackable cages allow you to store goods securely and visibly, making it easy for workers to access everything they need to fulfil orders quickly and accurately. With their durable and versatile design, these cages ensure your packing process is more efficient and organised, helping you avoid delays and enhance overall productivity.

Addressing standard warehouse picking errors and packing challenges is crucial for maintaining efficiency, reducing errors, and ensuring customer satisfaction. At QTS, we offer a wide range of innovative products to tackle these issues head-on. From optimising space with our Underslung Loop Dividers to preventing damage with our Rack Protectors, our solutions ensure your customer’s warehouse operates at peak efficiency. Investing in the right tools and systems can transform your picking and packing processes, boost productivity, and stay ahead in the competitive logistics industry.

Please get in touch with us today for more information on how QTS products can help optimise your warehouse. Let’s work together to build a more efficient and effective warehouse operation!