How to Increase Order Picking Accuracy and Reduce the Number of Complaints?

Main Causes of Picking Errors

Order picking errors are the result of many overlapping factors:

• Working with paper picking lists – manually entering data leads to transcription mistakes or misreading handwritten entries.
• No real-time validation system – without on-the-spot verification, employees may accidentally pack the wrong product or quantity.
• Rushing and time pressure – during peak hours or when handling large orders, the pressure to work quickly increases the likelihood of mistakes.
• Insufficient labeling of locations and products – unclear or missing labels make it harder to locate the correct items.
• Lack of system integration – for example, an order from the ERP system is not automatically transferred to the picking terminal, causing confusion.
• Poor workplace ergonomics – employees have to return to desktop stations repeatedly, carry bulky devices, or work with uncomfortable interfaces.

Example: A customer orders 10 units of product X, but due to outdated data in the system, the worker picks product Y. The customer files a complaint, the company bears the return costs, and the customer's trust is damaged.

Solutions That Improve Accuracy

To eliminate errors, it's worth implementing an automated picking system based on barcode scanning and mobile devices. Key components include:

• Barcode scanning – each item in the order is verified during picking. The system prevents the order from proceeding if the wrong item is scanned.
• ERP integration – the worker sees an up-to-date order list, product descriptions, images, and quantities directly on the terminal. This reduces the risk of errors and eliminates the need to return to the office.
• Warehouse location management – with defined zones and clearly labeled shelves and racks, employees don’t have to guess where items are stored.
• Product documentation access – images, instructions, and colour variants often determine correct product selection.

Implementation example: A trading company that previously averaged four complaints per day reduced picking errors to zero in the first month after implementing scanning-based picking with Zebra terminals.

Comfort and Precision with Zebra Devices

The hardware matters — it’s what your employees use all day. Zebra Technologies devices are purpose-built for warehouses and production environments:

Zebra MC3400 – ideal for large warehouse operations. Rugged construction, high performance, and long battery life.

Zebra TC22/TC27 – lightweight and ergonomic mobile terminals that resemble smartphones, perfect for mobile picking workflows.

Zebra DS3608 – industrial barcode scanner with extended range, built to withstand drops and harsh conditions.

All of these devices offer:

• fast and accurate scanning, even from longer distances,
• ease of use – even when wearing gloves,
• long battery life,
• resistance to moisture, dust, and impact,
• bright, high-visibility screens for any lighting condition.

End-to-End Implementation by MANUCO

Implementing a modern picking process doesn't stop at purchasing devices. The key is aligning the solution with your organization and training your team. At MANUCO, we:

• analyze the picking process step by step,
• recommend the best devices for your work environment,
• deliver software and integrate it with your ERP,
• design a clear and logical warehouse location structure,
• train your staff,
• support testing, development, and post-implementation optimization.