Increasing Order Accuracy in Your Fulfillment Center
Scott Hothem • December 16, 2013
A fundamental pillar of a strong fulfillment center is accuracy. Order accuracy is the one tangible, logistical element that ties your company to your consumer. As soon as a customer places an order for your product, whether your fulfillment provider recognizes it or not (and they should), a bond is formed. You’ve spent too much time, money, and effort enticing customers to purchase, just to have the ball dropped when they actually open their wallets. Breaking this trust with your consumer can be absolutely detrimental to your business and your brand. Besides damaging your company’s reputation, it has a significant impact to your margins and bottom line. A study by MHI shows that 39% of retail companies face a key challenge with inaccurate order delivery dates.
Fulfillment accounts for 50-60% of your labor expenses, far and away the most intensive and expensive costs your distribution center will incur. However, the massive significance of fulfillment operations in keeping your customers satisfied more than justifies this steep investment. And as with any investment, keeping tabs on the efficiency of the fulfillment performance is the only way to earn a return and avoid unnecessary delay and expenditures.
Observing your distribution center during a shift can provide a handful of reasons for your poor order accuracy results. In particular, two areas are likely having the greatest impact on your accuracy, or lack thereof. Stocking activity is typically a major component in fulfillment errors. A study by intelligrated.com shows that stocking activity is responsible for nearly a quarter of all order fulfillment mistakes.
Ideally, stocking is done before picking, synchronizing, or slotting. Performing these activities in this particular sequence will reduce the instances of having unavailable merchandise. Further, providing more slots for high-velocity items and separating similar type items from each other are two easy ways to reduce fulfillment errors. According to a Supply Chain Quarterly survey, stocking practices were a leading factor in 76% of companies with accuracy issues.
In addition to stocking activity, picking motions pose a tremendous threat to order accuracy. Creating the most efficient picking motion possible will alleviate many of the mistakes within your supply chain. Items that are difficult to reach or heavier products that are organized incorrectly increase the likelihood of inaccurate picking. Creating distinct zones for different types of products and balancing such zones with the appropriate equipment can reduce these concerns. Optimizing the picking protocol for a mid-sized retailer can improve order accuracy by 34%, as stated in a 2012 case study by Logistics Planning.
Given the urgency and utmost importance to deliver the correct order to your customers, there are proven methods you can put in place to increase your order accuracy. Partnering with a qualified fulfillment provider can be an effective way to enhance your order accuracy and has a direct correlation to your customer service, brand reputation, and bottom line.
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Choosing a third-party logistics (3PL) provider is one of the most important decisions a growing brand can make. The right partner doesn't just ship orders—they become an extension of your business, helping you scale operations, navigate retail requirements, and create a better customer experience. Welcome to Inside Barrett with Faith Artieda , a series that takes you behind the scenes at Barrett Distribution Centers. In each episode, Faith sits down with the people who power Barrett's success, exploring their roles, sharing their expertise, and answering the questions clients ask most about fulfillment, logistics, and supply chain management. For our first feature, Faith spoke with Scott Hothem , Senior Vice President of Customer Solutions , who has spent more than 14 years helping brands find logistics solutions that support long-term growth. From omnichannel fulfillment to choosing the right fulfillment partner, Scott shares what every business should know before selecting a 3PL. A 3PL Should Be More Than a Warehouse When companies begin searching for a fulfillment provider, many focus on the basics: warehouse locations, pricing, or square footage. While those factors matter, Scott believes they don't tell the whole story. "Every 3PL has warehouses, forklifts, and scanners," he explains. "The real question is whether they understand your business." A great logistics partner takes the time to understand your products, order profiles, customers, growth plans, and operational challenges before proposing a solution. Rather than offering a one-size-fits-all pricing sheet, they build a fulfillment strategy tailored to your business. At Barrett, that consultative approach has helped brands of all sizes successfully navigate periods of rapid growth and operational change. Why Omnichannel Experience Matters Today's brands rarely sell through just one channel. A customer may place an order through your Shopify store, while another purchases the same product on Amazon. At the same time, your largest retailer may submit a purchase order for thousands of units destined for stores across the country. Managing those channels requires more than warehouse space—it requires operational expertise. Scott explains that omnichannel fulfillment means seamlessly managing direct-to-consumer orders alongside wholesale and retail distribution while maintaining inventory accuracy, retailer compliance, and exceptional customer service. For brands expanding into retailers like Walmart, Target, Costco, or Nordstrom, choosing a 3PL with proven retail experience can help avoid costly compliance issues, chargebacks, and fulfillment delays. Ask the Right Questions Before Choosing a 3PL Instead of asking only about rates, Scott recommends asking prospective logistics providers questions like: Have you worked with companies similar to ours? How have you helped customers overcome growth challenges? Can your operations scale with our business? What retail partners do you currently support? What technology and reporting capabilities do you offer? How do you approach onboarding new customers? These conversations reveal far more about a provider's capabilities than pricing alone. The best 3PL relationships are built on transparency, collaboration, and shared goals—not simply transactional services. Price Is Important—But Value Matters More Every business wants competitive pricing, but the lowest quote isn't always the best investment. According to Scott, fulfillment pricing should reflect the complexity of a customer's operation—not a generic menu of services. Factors like SKU count, order volume, value-added services, inventory requirements, seasonality, and retail compliance all influence the most effective fulfillment solution. It's one reason Barrett develops customized proposals instead of standardized rate sheets. Scott notes that Barrett frequently reconnects with companies that initially selected a lower-cost provider only to discover that their fulfillment partner couldn't support their evolving business needs. Look for a Partner That Can Grow With You Growth is exciting—but it also introduces new operational challenges. A startup shipping a few hundred ecommerce orders today may find itself fulfilling thousands of daily orders or shipping to major retailers within a few years. Scott has seen that transformation firsthand. Over the years, Barrett has partnered with emerging brands from their earliest stages, helping many grow into nationally recognized companies generating hundreds of millions of dollars in annual revenue. That kind of long-term partnership is possible because Barrett focuses on building solutions that scale—not solutions that only solve today's challenges. Technology Should Enhance the Customer Experience Artificial intelligence has become one of the biggest conversations in logistics. While Barrett continues investing in automation, systems integrations, data analytics, and emerging technologies, Scott believes technology should enhance—not replace—the customer relationship. For Barrett, meaningful conversations still matter. When prospective customers reach out, they're connected with experienced professionals who understand fulfillment strategy, supply chain challenges, and operational execution—not an automated chatbot. Technology should make service better. It shouldn't replace the people behind it. Barrett's Biggest Competitive Advantage: Its People Throughout the conversation, one theme surfaced again and again: people. After more than 80 years in business, Barrett has built its reputation on experienced employees, long-term customer relationships, and a culture centered on continuous improvement. From warehouse associates to executive leadership, every team member plays a role in delivering exceptional customer experiences. That people-first mindset has helped Barrett build lasting partnerships with brands across apparel, health and beauty, consumer products, food and beverage, and other industries while continuing to invest in technology, facilities, and operational excellence. Final Thoughts Choosing a 3PL isn't simply about finding a warehouse—it's about finding a partner that understands your business, supports your growth, and shares your commitment to customer success. As Scott Hothem shared in this first edition of Inside Barrett , companies should look beyond pricing and ask deeper questions about experience, scalability, technology, and culture. Because when your logistics partner succeeds, your business has the opportunity to do the same. Stay tuned for future editions of Inside Barrett with Faith Artieda , where we'll continue introducing the experts behind Barrett Distribution Centers and answering the logistics questions that matter most to growing brands.
As businesses grow, managing inventory, shipping orders, and meeting customer expectations becomes increasingly complex. That's where a third-party logistics provider, or 3PL , can make a significant difference. A 3PL is a company that manages some or all of your supply chain operations, including warehousing, order fulfillment, transportation, inventory management, and value-added services. Instead of investing in your own warehouse, technology, and fulfillment staff, you partner with a logistics expert that has the infrastructure and expertise already in place. So, how do you know if it's time to make the switch? If your team is spending more time packing orders than growing the business, struggling to keep up with demand, or facing rising shipping costs, partnering with a 3PL may be the next step. Businesses also turn to 3PL providers when expanding into new markets, launching new sales channels, or looking to improve delivery speed without increasing overhead. The right 3PL does more than store inventory. It becomes an extension of your business, providing the technology, visibility, and operational support needed to scale efficiently. Features like real-time inventory tracking, transportation management, retail compliance, and value-added services help streamline operations while improving the customer experience. At Barrett Distribution, we provide customized third-party logistics solutions backed by more than 80 years of experience. Our nationwide network of strategically located fulfillment centers supports both B2B and direct-to-consumer operations, allowing customers to reach more consumers faster while maintaining inventory accuracy and operational efficiency. With advanced warehouse management technology, transportation solutions, and a dedicated customer support team, Barrett helps businesses simplify logistics so they can focus on growth. Whether you're a fast-growing ecommerce brand or an established manufacturer looking to optimize your supply chain, partnering with the right 3PL can reduce costs, improve service, and position your business for long-term success.
As your business grows, the warehouse that once supported your operations may start holding you back. What worked when you were shipping a few hundred orders a week may no longer be able to keep pace with rising order volumes, expanding sales channels, or increasing customer expectations. Recognizing the warning signs early can help you avoid fulfillment disruptions, rising costs, and dissatisfied customers. Here are seven indicators that it may be time to evaluate a new warehouse or 3PL partner. 1. Orders Are Taking Longer to Ship Today's customers expect fast, reliable delivery. If order processing times are increasing or you're struggling to meet shipping deadlines, your warehouse may have reached its capacity. Delays can impact customer satisfaction, retailer scorecards, and your brand's reputation. At Barrett Distribution, our facilities are supported by advanced warehouse management technology and engineered processes designed to maintain fast, accurate fulfillment as order volumes grow. 2. Inventory Accuracy Is Becoming a Challenge Frequent inventory discrepancies, stockouts, or overselling are often signs that your current operation lacks the systems and controls needed to scale. Modern warehouses should provide real-time inventory visibility, robust cycle counting programs, and reliable lot and expiration tracking where required. Barrett combines these inventory controls with customer reporting and analytics to help businesses make informed supply chain decisions. 3. You're Selling Across More Channels Many businesses now serve retailers, ecommerce customers, marketplaces, and wholesale distributors simultaneously. If your warehouse struggles to manage different order requirements, routing guides, or compliance standards, it may not be equipped for true omnichannel fulfillment. Barrett specializes in supporting both B2B and direct-to-consumer fulfillment from the same network, helping brands maintain consistent service levels across every sales channel. 4. Your Warehouse Can't Scale with Seasonal Demand Peak seasons shouldn't require scrambling for labor or turning away business. A warehouse partner should have the space, workforce, and operational processes to scale alongside your business during promotions, product launches, and holiday demand. With more than 6 million square feet of warehouse space across multiple U.S. markets, Barrett provides customers with the flexibility to grow without constantly worrying about capacity constraints. 5. You Have Limited Visibility into Your Operations If you're relying on spreadsheets or waiting for someone to send reports, you're missing valuable opportunities to improve performance. Today's logistics operations should provide real-time access to inventory, order status, shipping metrics, and key performance indicators. Barrett's customer portal and embedded analytics give customers greater visibility into their operations, helping them identify trends and make data-driven decisions. 6. Transportation Costs Continue to Rise Your warehouse location has a direct impact on shipping costs and delivery times. If you're shipping nationwide from a single facility that no longer aligns with your customer base, transportation expenses can quickly increase. Barrett's nationwide fulfillment network allows businesses to position inventory closer to customers, reducing transit times while helping optimize parcel and freight costs. 7. Your 3PL Feels Like a Vendor, Not a Partner Perhaps the biggest sign you've outgrown your current warehouse is the relationship itself. A strong 3PL should do more than process orders—it should proactively recommend improvements, communicate regularly, and help your business adapt as it grows. At Barrett, every customer is supported by dedicated operations teams, strategic account management, and a culture of continuous improvement. From onboarding through ongoing optimization, the focus is on building long-term partnerships that evolve alongside each customer's business. Is It Time to Reevaluate Your Fulfillment Strategy? Growth is a good problem to have—but only if your logistics operation can keep up. If any of these signs sound familiar, it may be time to assess whether your current warehouse is supporting your long-term goals. With more than 80 years of experience, a nationwide network of strategically located facilities, advanced technology, and expertise across ecommerce, retail, and omnichannel fulfillment, Barrett Distribution helps businesses scale with confidence. The right warehouse partner doesn't just store inventory—it becomes an extension of your business, helping you deliver a better experience to your customers every step of the way.
