5 Common Picking Errors in the Warehouse (and How to Prevent Them)

Picking errors: an underestimated problem

A picking error — the wrong product, the wrong quantity, or a missing item — may seem like a small problem. But the consequences are bigger than you think: returns, extra shipping costs, customer service workload, and in the worst case, losing a customer. Moreover, picking errors are often structural: the same mistakes keep coming back.

The 5 most common picking errors

1. Wrong product picked

The most common error: the employee grabs a different product than what was ordered. This often happens with products that look alike — in packaging, color, or size. Without verification at the moment of picking, the error is only discovered by the customer.

Prevention: Barcode scanning during picking creates an immediate check. The system compares the scanned code with the expected code and warns on a mismatch.

2. Wrong quantity

Too many or too few products in the order. This often occurs with orders containing larger quantities of the same product, or when employees work under time pressure.

Prevention: Digital pick lists show the exact quantities per product. With scanning, the system can track how many units have already been scanned.

3. Product not found

The employee cannot find the product at the indicated location. This can be caused by incorrect location records, a product put back in the wrong place, or inventory that is not up to date.

Prevention: Accurate location records and digital location guidance help employees find the right spot faster. With recurring problems, the data can reveal which locations or products cause issues most often.

4. Orders mixed up

Products intended for one order end up in the box of another order. This risk is greater when employees pick multiple orders at the same time.

Prevention: Picking one order at a time through a digital system reduces the risk of mix-ups. The employee focuses on one order and completes it before starting the next.

5. Damaged product included

A product with damaged packaging or visible damage gets packed without anyone noticing. In paper-based processes, there is no moment when this is explicitly checked.

Prevention: Some digital picking systems offer the option to add a quality control step to the picking process, so employees explicitly confirm the product is in good condition.

The cost of picking errors

Picking errors are more expensive than they appear. Consider:

• Return costs: Shipping costs for collecting the wrong order and resending the correct one.
• Processing costs: Customer service time, returns handling, and repacking.
• Customer loss: Customers who receive a wrong order are less likely to order again.
• Inventory discrepancies: Incorrectly shipped products disrupt inventory records.

From reactive to preventive

Most warehouses only discover picking errors after the fact — through complaints, returns, or inventory discrepancies. Digital order picking software turns this around: errors are flagged the moment they occur, not days later. That difference is the difference between solving a problem and preventing one.

Summary

Picking errors are rarely the result of carelessness. They are the result of processes that lack sufficient checks. By building in verification steps — such as barcode scanning and digital pick lists — you can tackle the most common errors structurally.

Further reading

• Order picking software — Prevent errors with scan verification
• QR code scanning — Instant product verification with your phone
• 7 tips to optimize your order picking