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.

Recent Blog Posts

By Faith Artieda May 7, 2026
On May 4, 2026, our Franklin, MA facility achieved a milestone that reflects that commitment: a perfect score of 1000 on its AIB (American Institute of Baking) food safety audit—the first perfect score in Barrett history. For brands operating in food, beverage, and consumable categories, this achievement represents more than a number. It’s a clear signal of the discipline, consistency, and attention to detail required to protect product integrity across the supply chain. What an AIB Audit Measures—and Why It Matters An AIB audit is one of the most rigorous food safety evaluations in the industry. It assesses a facility’s ability to maintain: Cleanliness and sanitation standards Operational controls and process discipline Regulatory compliance and documentation Facility maintenance and structural integrity For brands, especially those managing consumable or regulated products, these standards are critical. A failure in any of these areas can lead to product risk, compliance issues, or damage to brand reputation. From 990 to 1000: A Culture of Continuous Improvement The Franklin team’s achievement didn’t happen overnight. After earning an outstanding score of 990 in the previous audit, the team set a clear and ambitious goal: reach a perfect 1000. What followed was a disciplined, detail-oriented approach to closing every gap. Through weekly audit preparation calls, consistent follow-up, and a strong focus on execution, the team elevated every aspect of the operation. The result was a facility operating at the highest possible standard—where even the smallest details were addressed. Floors were spotless, the environment was free of dust and debris, and every element of the building met or exceeded expectations. This wasn’t incremental improvement. It was precision execution. Operational Excellence Is a Team Effort Achievements like this reflect the strength of the entire operation—not just one function. From operations leadership and supervisors to safety and maintenance teams, every role contributed to the outcome. Strong documentation, proactive facility upkeep, and disciplined daily execution all played a part in achieving a perfect score. This level of alignment is what enables Barrett to deliver consistent, reliable performance for customers in highly regulated industries. What This Means for Barrett Customers For brands evaluating a 3PL partner, certifications and audit scores aren’t just credentials—they’re indicators of how your product will be handled every day. A perfect AIB score demonstrates: A food-safe, audit-ready environment Strong inventory and process controls A culture built on accountability and continuous improvement Confidence that your products are handled with the highest level of care For customers in food, beverage, health, and beauty, that level of rigor directly translates to reduced risk and stronger operational performance. Setting the Standard Moving Forward This milestone is a proud moment for the Franklin team—but it also reflects something broader across Barrett. Our approach to warehousing and fulfillment is rooted in discipline, visibility, and execution. Whether supporting food-grade operations or complex omnichannel distribution, we focus on delivering consistent results at scale.  Because in today’s supply chain environment, excellence isn’t occasional—it has to be repeatable.
By Faith Artieda April 23, 2026
How Barrett eliminates inefficiencies across the supply chain to reduce waste, lower costs, and improve performance.
Choosing a 3PL Partner: What Matters Most?
By Megan Krauss April 20, 2026
Choosing a 3PL partner? See what matters most to brands, from customer service and inventory accuracy to speed and technology.
More Posts