Common Order Picker Mistakes at Work

Are you an Order Picker aiming for peak performance? Avoiding common pitfalls can significantly boost your efficiency and accuracy. This isn’t about generic advice; it’s about the specific traps that Order Pickers face daily. By the end of this article, you’ll have a checklist to prevent errors, a rubric to evaluate your picking process, and scripts to communicate effectively with warehouse staff.

What You’ll Walk Away With

• A 20-point checklist to prevent picking errors before they happen.
• A rubric to score your picking efficiency and identify areas for improvement.
• Three ready-to-use scripts for communicating issues to supervisors and colleagues.
• A prioritization framework to decide which orders to pick first based on urgency and efficiency.
• A clear understanding of the red flags that hiring managers watch out for in Order Pickers.
• A 7-day action plan to improve your picking accuracy and speed.

Scope of This Article

This is about avoiding common mistakes in order picking. This is not about general warehouse management or forklift operation.

The High Cost of Picking Errors

Picking errors directly impact the bottom line. Incorrect orders lead to returns, customer dissatisfaction, and increased shipping costs. A single error can trigger a chain reaction, disrupting the entire fulfillment process.

Mistake #1: Ignoring the Pick List

Order Pickers sometimes rely on memory instead of the pick list. This leads to selecting the wrong item or quantity. Always double-check the pick list before and after selecting an item.

Mistake #2: Misreading Location Codes

Confusing similar-looking location codes is a common error. A simple misread (e.g., B12 instead of B21) can lead to picking from the wrong bin. Slow down and verify each digit or letter.

Mistake #3: Rushing the Process

Pressure to meet deadlines can lead to rushing, increasing the likelihood of errors. While speed is important, accuracy should always be the priority. A slow, accurate pick is better than a fast, incorrect one.

Mistake #4: Poor Communication with Warehouse Staff

Failing to communicate low stock or damaged items can cause delays and further errors. If you notice a discrepancy, immediately inform your supervisor or inventory control team.

Mistake #5: Neglecting Equipment Maintenance

Using faulty equipment, such as scanners with low batteries, can lead to missed scans and incorrect data entry. Regularly inspect and maintain your equipment to ensure proper functioning.

Mistake #6: Not Reporting Discrepancies

Ignoring discrepancies between the pick list and the actual inventory creates larger problems down the line. If something doesn’t match up, document it and report it immediately.

Mistake #7: Skipping Quality Checks

Failing to perform a final quality check before sending the order to packing can allow errors to slip through. Take a moment to verify the items and quantities against the pick list one last time.

A 20-Point Checklist to Prevent Picking Errors

Use this checklist before each shift to minimize errors. This proactive approach can significantly improve your picking accuracy.

1. Verify scanner is fully charged.
2. Inspect cart for damage.
3. Review pick list for special instructions.
4. Confirm location code before picking.
5. Double-check item description.
6. Count quantity carefully.
7. Scan item barcode.
8. Visually inspect item for damage.
9. Report any discrepancies immediately.
10. Communicate low stock levels.
11. Maintain a clean work area.
12. Avoid distractions.
13. Take breaks to prevent fatigue.
14. Use proper lifting techniques.
15. Wear appropriate safety gear.
16. Follow warehouse procedures.
17. Ask questions if unsure.
18. Document any errors found.
19. Participate in training sessions.
20. Contribute to process improvement suggestions.

Rubric for Evaluating Order Picking Efficiency

Use this rubric to assess your picking performance and identify areas for improvement. This provides a structured way to track progress.

• Accuracy (50%): Percentage of orders picked without errors.
• Speed (30%): Time taken to complete a pick list.
• Communication (10%): Effectiveness in reporting discrepancies and low stock.
• Equipment Maintenance (10%): Proper care and use of equipment.

Three Scripts for Effective Communication

Use these scripts to communicate common issues to supervisors and colleagues. Clear communication is key to preventing further problems.

Use this when reporting a discrepancy to your supervisor.

“Hi [Supervisor’s Name], I’ve encountered a discrepancy on pick list [Pick List Number]. The item count for [Item Name] is off by [Quantity]. What’s the next step?”

Use this when informing a colleague about low stock.

“Hey [Colleague’s Name], just a heads up that we’re running low on [Item Name] in location [Location Code]. You might want to check inventory levels.”

Use this when reporting damaged merchandise.

“Hi [Supervisor’s Name], I found damaged merchandise while picking item [Item Name] on pick list [Pick List Number]. I’ve documented the damage. How should I proceed?”

Prioritization Framework: Which Orders to Pick First

Prioritize orders based on urgency and picking efficiency. This ensures timely fulfillment and maximizes productivity.

• High-Priority Orders: Orders with tight deadlines or express shipping.
• Short Pick Lists: Orders with a small number of items and easily accessible locations.
• Consolidated Picks: Orders that can be picked efficiently by combining items from the same area.

What a Hiring Manager Scans for in 15 Seconds

Hiring managers quickly assess Order Picker candidates. They look for specific signals of competence and reliability.

• Experience with warehouse management systems (WMS).
• Proven track record of accurate order picking.
• Strong attention to detail.
• Ability to work efficiently under pressure.
• Excellent communication skills.
• Commitment to safety procedures.

The Mistake That Quietly Kills Candidates

Failing to quantify your accomplishments is a critical mistake. Generic statements like “improved efficiency” don’t impress hiring managers. Provide specific metrics and examples.

Use this improved resume bullet instead of a generic statement.

“Improved order picking accuracy by 15% in Q3 by implementing a new barcode scanning system, reducing return rates and saving the company $5,000 in shipping costs.”

7-Day Action Plan to Improve Picking Performance

Follow this plan to see tangible improvements in your picking accuracy and speed within a week. This is a practical way to implement the strategies discussed.

1. Day 1: Review the 20-point checklist and implement it.
2. Day 2: Track your picking accuracy and speed using the rubric.
3. Day 3: Practice using the communication scripts.
4. Day 4: Prioritize orders using the framework.
5. Day 5: Identify and address one area for improvement based on your rubric scores.
6. Day 6: Continue tracking your performance.
7. Day 7: Review your progress and adjust your strategies as needed.

FAQ

What are the most common causes of order picking errors?

The most common causes include misreading location codes, rushing the process, ignoring the pick list, poor communication with warehouse staff, and neglecting equipment maintenance. Addressing these issues proactively can significantly reduce errors.

How can I improve my order picking speed without sacrificing accuracy?

Focus on optimizing your workflow, such as organizing your cart efficiently and planning your route through the warehouse. Also, ensure you are familiar with the location of frequently picked items. However, never prioritize speed over accuracy.

What should I do if I find a discrepancy between the pick list and the actual inventory?

Immediately report the discrepancy to your supervisor or inventory control team. Provide as much detail as possible, including the item name, location code, and the nature of the discrepancy. Document the issue and follow your company’s procedures for resolving inventory discrepancies.

How important is it to scan each item before placing it in the order container?

Scanning each item is crucial for maintaining accurate inventory records and preventing picking errors. It provides a digital confirmation that the correct item has been selected and helps to track the movement of goods within the warehouse. Always prioritize scanning each item.

What are some strategies for dealing with pressure to meet tight deadlines?

Communicate any concerns about meeting deadlines to your supervisor as early as possible. Offer potential solutions, such as prioritizing certain orders or requesting additional assistance. Focus on maintaining accuracy, even when under pressure.

How can I stay organized and efficient while picking multiple orders simultaneously?

Use a well-organized cart with separate compartments for each order. Clearly label each compartment and double-check the pick list before placing items in the corresponding container. Plan your route to minimize backtracking and maximize efficiency.

What types of safety precautions should I take while order picking?

Wear appropriate safety gear, such as steel-toed shoes and gloves. Use proper lifting techniques to avoid injuries. Be aware of your surroundings and watch out for other workers and equipment. Report any safety hazards to your supervisor immediately.

How can I effectively communicate with other warehouse staff to ensure smooth order fulfillment?

Use clear and concise language when communicating with other staff members. Be respectful and professional at all times. If you have any questions or concerns, don’t hesitate to ask for clarification. Share information about low stock levels or damaged items promptly.

What are some common mistakes to avoid when using a handheld scanner?

Ensure the scanner is properly focused and positioned before scanning. Avoid scanning items in direct sunlight or under bright lights, as this can interfere with the scanning process. Replace the batteries regularly to prevent the scanner from malfunctioning.

How can I ensure that I am picking the correct quantity of each item?

Take your time and count the items carefully. Double-check the quantity against the pick list before and after selecting the items. If you are picking multiple items from the same location, use a counting aid, such as a scale or a counting board.

What is the best way to handle damaged merchandise that I encounter while order picking?

Do not pick the damaged merchandise. Report the damage to your supervisor immediately. Provide as much detail as possible about the nature and extent of the damage. Follow your company’s procedures for handling damaged merchandise.

How can I contribute to process improvement suggestions to improve order picking efficiency?

Pay attention to the challenges and inefficiencies you encounter while order picking. Brainstorm potential solutions and share them with your supervisor or process improvement team. Be specific and provide data to support your suggestions. Be open to feedback and willing to collaborate with others.

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