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Warehouse Management Best Practices: Reducing Picking Errors with Better Layout & Scanning

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Warehouse Management Best Practices: Reducing Picking Errors with Better Layout & Scanning

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      "Quick Picks": Your At-a-Glance Takeaways

      • Picking errors can cost warehouses thousands in returns, delays, and poor customer experience
      • Optimised warehouse layout improves picker navigation and reduces mistakes
      • Scanning tech (like barcode & RFID) boosts accuracy by verifying items in real-time
      • Cluster picking, zone picking and bin labelling reduce travel time and errors
      • Integrating WMS like NetSuite WMS ensures seamless tracking and scanning
      • Middle East warehouses face unique layout challenges – climate, labour, and speed expectations
      • Omniful’s AI-powered WMS optimises layouts and scanning for fast, error-free operations

      Why Warehouse Layout and Scanning Matter Now More Than Ever

      In today’s fast-moving e-commerce world, one late delivery or incorrect order can damage your reputation. Warehouses are no longer just storage facilities – they are fulfilment powerhouses. This is especially true in the MENA region, where fast delivery and high accuracy are the norm, not the exception.

      In fact, McKinsey reports that 45% of logistics costs are tied to warehousing. Errors in picking — the process of retrieving items for orders — not only waste time but can also erode customer trust.

      So how can warehouses reduce picking errors? The answer lies in two often-overlooked areas: smarter layouts and real-time scanning.

      The Real Cost of Picking Errors

      Picking errors go beyond wrong items. They lead to:

      • Delays in shipping
      • Higher return and restocking costs
      • Dissatisfied customers
      • Increased manual checks and rework

      In a survey by VDC Research, 62% of warehouse operators cited picking errors as a top reason for operational inefficiency.

      Designing a Smarter Warehouse Layout

      Warehouse design should not be static. It should evolve with SKU velocity, seasonal changes, and product demand.

      What Makes a Layout "Smart"?

      • ABC Analysis: Store high-frequency items closest to the packing area.
      • Zoned Picking: Divide the warehouse into zones to cut down walking time.
      • Vertical Space Use: Go upwards with mezzanines or racks to increase efficiency.
      • Clear Labelling & Signage: Helps pickers find items quickly, even new hires.

      Middle East Focus

      In regions like the UAE and KSA, warehouses face extreme heat and energy constraints. Layouts should factor in cooling zones, fast access paths, and ergonomic stations to reduce picker fatigue.

      Scanning: The Unsung Hero of Accuracy

      Gone are the days of pen-and-paper picking. Scanning tools ensure the right item is picked every time.

      Tools That Make a Difference

      • Barcode Scanners: Handheld or wearable devices that confirm item identity instantly.
      • RFID Tags: Enable real-time item tracking without line-of-sight scanning.
      • Mobile Apps: Enable scanning, updating, and syncing on the go — like Omniful’s picker app.

      Why It Works

      Scanning minimises human error and enables traceability. Paired with a WMS like NetSuite WMS or Omniful, each scan updates inventory in real-time.

      Without a strong WMS, even the best scanning tools fall short.

      What a Good WMS Should Do

      • Map bin locations to item barcodes
      • Track picker performance
      • Enable route optimisation for picking tasks
      • Sync inventory across online and offline channels

      Platforms like NetSuite WMS and Omniful’s WMS allow warehouses to track, pick, and ship faster with fewer mistakes. Omniful, in particular, is built for MENA-specific challenges like dark store models, multi-brand warehousing, and high-volume SKUs.

      Local Case Study: How Laverne in KSA Reduced Picking Errors

      Laverne, a leading D2C brand in Saudi Arabia, moved away from 3PLs to manage their own fulfilment. After adopting Omniful’s WMS, they:

      • Reduced order-to-delivery time from 4–6 days to just 2–3 hours in Riyadh
      • Achieved 100% picking accuracy
      • Eliminated 3PL costs by optimising in-house layout and scanning

      This proves how layout and tech combined can transform fulfilment.

      Practical Steps to Reduce Picking Errors in Your Warehouse

      1. Conduct a layout audit – Use ABC analysis and optimise travel paths.
      2. Invest in scanning tech – Handheld or wearable, matched to your WMS.
      3. Train pickers using tech – Ensure they understand how to follow scan prompts.
      4. Track picker performance – Use KPIs to spot where errors originate.
      5. Use batch or cluster picking – Pick multiple orders in fewer walks.
      6. Regularly review SKU placement – Adjust layout with changing demand.
      7. Implement WMS route optimisation – Especially critical in large or multi-zone warehouses.

      Why This Matters for MENA Businesses

      Warehouses across the Middle East are scaling fast — thanks to the boom in e-commerce, retail, and grocery delivery. But fast growth without accurate fulfilment is a recipe for churn.

      With smart layouts, scanning tools, and WMS integration, companies in Saudi Arabia, the UAE, and beyond can meet the high expectations of today’s customers — without adding unnecessary costs.

      Ready to Eliminate Picking Errors?

      Discover how Omniful’s Warehouse Management System can supercharge your accuracy, cut down order times, and future-proof your operations.

      👉 Book a Demo

      FAQs

      What’s the most common picking error in warehouses?
      Mis-picks — picking the wrong SKU due to poor labelling or lack of scanning — are the most common.

      Is RFID better than barcodes?
      RFID is faster and doesn’t require line-of-sight, but it’s more expensive. Barcodes remain cost-effective for most MENA warehouses.

      Can layout really reduce errors?
      Yes. Poor layout increases picker travel time and mental load, which leads to more errors.

      What is zone picking?
      It divides the warehouse into zones, with pickers assigned to one area. This reduces walking and boosts speed.

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