Enhancing Warehouse Accuracy and Efficiency through Digital Picking Systems

Our client, a logistics company specializing in third-party warehousing and distribution, struggled with high error rates and delays in their manual order picking processes. With multiple clients and thousands of SKUs, their reliance on paper-based instructions led to misplaced items, wrong shipments, and customer dissatisfaction.

Problem

The client identified multiple operational pain points:

• Manual Picking Errors: Paper-based lists caused confusion and item mismatches, especially during peak seasons.
• Inefficient Use of Labor: Workers spent excessive time locating items and double-checking orders.
• Lack of Real-Time Inventory Visibility: Management lacked instant insight into stock levels and picking performance.
• High Return Rates: Errors in picking directly impacted customer satisfaction and created costly return handling.

Objectives

The goal of the project was to address operational inefficiencies by introducing scalable, digital processes. Specifically, the client aimed:

• To standardize and digitize warehouse picking workflows.
• To minimize human error during order fulfillment.
• To gain real-time visibility into inventory and workforce performance.
• To increase labor productivity without expanding headcount.

Solution

ProcessNavigation implemented a mobile-enabled digital picking system:

• Smart Pick Lists: Digitally generated and prioritized picking instructions with item locations and photos.
• Mobile Devices with Barcode Scanning: Each picker used handheld scanners to confirm item accuracy in real-time.
• Live Dashboard for Supervisors: Real-time monitoring of picking progress and error alerts.
• Performance Analytics: Picker performance was tracked to identify training needs and optimize workflows.

Results

The client achieved:

• Improved accuracy and consistency in order picking.
• Reduced return handling and operational costs.
• Enhanced real-time visibility into inventory and workforce performance.

Conclusion

The introduction of digital picking transformed warehouse accuracy and efficiency. The client gained control over previously chaotic processes, delivering better service to their end clients while improving internal resource utilization.