42% reduction in shipping errors in a warehouse
We reorganized the packing zone and introduced QR code verification. The number of returns dropped by nearly half in two months.
The Bud-Max wholesaler was losing real money on incorrect shipments. Goods were leaving for customers mixed up, generating a avalanche of returns and angry phone calls. We entered the warehouse to locate the bottleneck and stop this cash leak.
The challenge
In March 2023, the company recorded 74 serious errors out of 1,184 completed orders. Each such error cost an average of 167.50 PLN, including round-trip transport and employee time for repacking. Warehouse workers worked in constant stress, and the packing zone resembled a battlefield where finding a free roll of tape took several minutes. The biggest problem was the lack of any outgoing control — no one checked if what was on the pallet matched the invoice.
Our approach
For the first 11 business days, our consultant, Robert Mazur, stood on the floor with a watch and noted every employee movement. It turned out that Ms. Edyta and Mr. Marek lost 19.3% of their time just looking for packing materials. Instead of buying an expensive ERP system for hundreds of thousands, we focused on the 5S method and simple improvements. We changed the shelf layout so that the most frequently ordered products were at hand. We also introduced the rule that the packing table must be empty before starting the next order.
The solution
We implemented a verification system based on QR codes and cheap wireless scanners. Now every product must be scanned before being put into the box. If an employee picks the wrong item, the system immediately generates a loud warning signal. Additionally, we improved the lighting in the control zone by 340 lux, as previously in the dim light it was easy to confuse similar cans of paint. The whole thing started working starting tomorrow after a short, 45-minute crew training.
Results
The warehouse began to work rhythmically and without nerves. The number of complaints dropped drastically because the system physically prevents sending the wrong goods. The company regained time previously wasted on processing returns and correcting invoices.
Timeline
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January 2024Work time measurements and analysis of error causes on the floor.
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February 2024Reorganization of packing stations according to 5S principles.
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March 2024Lighting installation and launch of QR scanners.
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April 2024Process stabilization and final results measurement.
"I was afraid that new technology would only slow the boys down and make their job harder. However, QR scanners shortened packing time by over 3 minutes per package. Now we have peace of mind from angry customer calls."