Warehouse accuracy is a critical determinant of customer satisfaction, operational efficiency, and cost control. Picking errors—such as wrong items, incorrect quantities, or missed picks—lead to returns, rework, delayed shipments, and loss of customer trust. This playbook provides a structured approach to eliminating picking errors through process optimisation, automation technologies, data-driven controls, and workforce best practices. It is designed for operations leaders, warehouse managers, and supply chain teams seeking measurable improvements in accuracy and fulfillment performance. Introduction ELIMINATING PICKING ERRORS WITH AUTOMATION & BEST PRACTICES Even small error rates can result in significant downstream costs. The Cost of Picking Errors Common Impacts Increased returns and reverse logistics costs Additional labor for re-picking and re-shipping Inventory inaccuracies and stock discrepancies Delayed order fulfillment Customer dissatisfaction and lost repeat business Typical Cost Drivers Manual picking and paper-based processes Poor slotting and warehouse layout Inadequate training and standardization Lack of real-time inventory visibility High SKU complexity and order variability Manual & Reactive Barcode-Enabled System-Directed Picking Automation-Assisted Picking Highly Automated & Intelligent Organisations progress through the following stages: Warehouse Accuracy Maturity Model Each stage reduces human error while increasing consistency and throughput. Process-Related Poorly defined picking workflows Inconsistent procedures across shifts Inadequate exception handling Layout & Slotting Similar SKUs stored close together Poor labeling and signage Inefficient pick paths System & Data Issues Inaccurate inventory master data Delayed inventory updates Poor WMS configuration Human Factors Fatigue and high pick rates Insufficient training Language or communication barriers Understanding error sources is essential before automation. Root Causes of Picking Errors ELIMINATING PICKING ERRORS WITH AUTOMATION & BEST PRACTICES Barcode & RFID Scanning Automation Technologies for Error Reduction Validates item, location, and quantity Prevents incorrect picks in real time Pick-to-Light / Put-to-Light Visual indicators guide pickers Ideal for high-volume, fast-moving SKUs Voice Picking Hands-free, eyes-free operation Reduces cognitive load and improves accuracy Vision Picking & Wearables Augmented reality overlays guide pick actions Improves speed and accuracy in complex environments Robotics & Goods-to-Person (GTP) Robots bring items to pickers Eliminates travel errors and mis-picks ELIMINATING PICKING ERRORS WITH AUTOMATION & BEST PRACTICES Best Practices for Accurate Picking Tigernix Pte Ltd Tel: +(65) 6760 6647 / +(65) 6760 6012 Email: info @tigernix.com Address: 21, Woodlands Close, #05-47 Primz Bizhub, Singapore 737854 www.tigernix.com Directed picking and task prioritisation Real-time inventory updates Slotting and wave optimisation Exception management and alerts Integration with automation systems ELIMINATING PICKING ERRORS WITH AUTOMATION & BEST PRACTICES Key WMS Capabilities Clearly defined SOPs for each pick method Consistent workflows across shifts and sites Warehouse Slotting Optimisation ABC analysis for SKU placement Separate look-alike and sound-alike items Re-slot based on demand patterns Error-Proofing (Poka-Yoke) Mandatory scans at pick and pack Weight checks at packing stations System-enforced validations Quality Checks & Audits Random pick audits Cycle counting integrated with picking Standardised Picking Processes Conclusion Eliminating picking errors requires a holistic approach that combines standardised processes, intelligent automation, robust systems, and an accuracy-focused culture. By following this playbook, organizations can significantly reduce errors, improve customer satisfaction, and achieve sustainable operational excellence.