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Cutting Warehouse Errors from 1.77% to 0.18%

Cutting Warehouse Errors from 1.77% to 0.18%

The Company

A mid-size Dutch e-commerce 3PL processing 300 – 500 orders per day across two shifts facing warehouse errors. Tools stack included ChannelDock (WMS), ClickUp, Zoho, PrintNode and various scanners/printers.

The Problem

The fulfilment operation was struggling with a rising error rate. In March 2024 accuracy dropped to 1.77 percent, well above the acceptable 1% threshold. Teams faced daily issues like:

  • pickers searching for products due to inconsistent locations
  • visual checks instead of scan confirmation
  • mixed waves that gave complex orders to new staff
  • no dedicated lane to handle problem orders
  • recurring CS tickets and returns due to packing mistakes

What I did to fix warehouse errors

I spent one year tightening processes, reconfiguring tools and reducing points of failure:

Process & Workflow

  • rebuilt the warehouse location schema and signage
  • enforced scan-to-complete at packing
  • split waves so juniors got simple orders, seniors handled complex ones
  • created a quarantine lane so exceptions stopped blocking flow

System & Configuration

  • redesigned batch types (single, multi, heavy, no-EAN)
  • automated label printing via PrintNode only after all items were scanned
  • blocked partial/unknown shipping states to avoid silent errors

Automations & Tools

  • Python + Apps Script jobs to surface fast movers, block bad orders, and highlight exceptions
  • daily exception reports and a live “error feed” for team leads

Hardware & Floor Setup

  • added fixed scanners, reorganised printer layout
  • set up manager station for fast issue resolution

The Result

Within 12 months the error rate dropped from 1.77% to 0.18% (audited April 2025). Secondary improvements included:

  • fewer returns and customer support tickets
  • smoother throughput during peak
  • faster pick/pack times
  • more predictable performance across shifts

PS: The spike you see in January 2024 was caused by a warehouse relocation which disrupted some of the operations.

What We Learned

  • Fix process first, configure apps second, automate last
  • Never rely on visual checks — scan everything
  • Protect flow by moving exceptions away from pickers
  • Keep a live error dashboard and review issues weekly

Want this for your warehouse?

I can review your tools, workflows and errors and show you where the leaks are. Book a free call.