Faster Order Picking, Fewer Errors – How Zebra Improves Warehouse Operations

Problem: Mixed-up Products, Picking Errors, Unreadable Labels

Many companies still rely on manual order picking – an employee walks through the warehouse with a printout, searches for products, checks off items, and hopes nothing is missed. In theory, this works. In practice – it leads to massive losses. A single mistake can mean product returns, extra transport, repicking, and loss of margin.

Labels are also an issue – often printed on cheap office printers, with no standardisation. Illegible barcodes, inconsistent formats, missing batch or expiry information – all of this complicates workflows and creates chaos in documentation.

For larger-scale operations, real-time updates become a challenge. When stock levels change constantly but the ERP system isn’t up to date, employees make decisions based on outdated information. This leads to overpicking, shortages, and unnecessary confusion in the shipping area.

Inefficient picking also means higher costs – employees cover unnecessarily long distances in the warehouse, the time to prepare a single package increases, and errors grow along with fatigue. It’s hard to optimise anything without proper data.

Finally – the lack of a unified system means no reports and no insights. How long does picking take? Which products are most problematic? Who makes the most mistakes? Without a digital system, these questions are hard to answer.

Solution: A Digital Warehouse with Zebra Technologies

Zebra technologies, combined with a well-designed application, can dramatically transform warehouse operations. Instead of paper – mobile touch-screen terminals. Instead of manual searching – barcode scanning and system prompts. Instead of guesswork – real-time data.

Implementing a solution based on Zebra scanners, terminals, and label printers automates the order picking process. The worker receives a pick list on the terminal with location, quantity, and collection order. After each scan, the system confirms accuracy and moves to the next item.

In one of our projects, we deployed Zebra TC2X mobile terminals and ZD421 label printers in a dynamic warehouse handling over 300 orders per day. Before the implementation, the average picking time per package was 11 minutes – after optimisation, it dropped to 6 minutes. Moreover, errors decreased by over 80%, and staff turnover stopped being an issue, as the system is user-friendly and requires minimal training.

An added benefit is the ability to generate clear, standardised labels with barcodes and extra information (packing date, batch number, series). This makes shipping, returns, and product tracking much easier.

The system can be integrated with ERP, WMS, or a custom app built in FileMaker. This ensures real-time data flow to the central system, making warehouse management predictable and measurable.

Why Zebra Technologies?

• Devices built for warehouse conditions – resistant to drops, dust, moisture, and heavy use.
• Readability and ergonomics – large screens, intuitive interface, accurate scanners.
• Industrial-grade label printers – fast, reliable, and compatible with various systems.
• IT system compatibility – full integration with ERP, WMS, FileMaker, and more.
• Scalability – from a few devices in a small warehouse to hundreds in a large logistics network.

How MANUCO Helps

MANUCO designs and implements complete warehouse solutions – from needs analysis and equipment selection to system integration and team training. We tailor the technology to your working conditions, budget, and operational scale.

We also build custom applications for picking, inventory, and labelling – fully compatible with Zebra terminals and warehouse management systems. Everything runs in real-time, and users can operate the system without days of training.

Thanks to our experience, you can be sure that the system will be stable and efficient – and your employees will work faster, more accurately, and without stress.