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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Reducing fulfillment errors starts with implementing standardized processes, leveraging warehouse technology, training employees consistently, and partnering with an experienced third-party logistics (3PL) provider. By improving inventory accuracy and quality control, businesses can minimize costly mistakes while delivering a better customer experience. Key Takeaways Standardized warehouse processes and employee training help reduce picking, packing, and shipping errors. Warehouse technology, including a Warehouse Management System (WMS) and barcode scanning, improves inventory accuracy and order visibility. Partnering with an experienced 3PL can help businesses achieve consistent fulfillment performance while scaling operations efficiently. Why Are Fulfillment Errors So Costly? Even small fulfillment mistakes can have a significant impact on a business. Shipping the wrong item, sending an incomplete order, or delivering a package late often leads to additional shipping costs, product returns, customer service inquiries, and dissatisfied customers. As order volumes grow, these issues become more difficult to manage without the right processes in place. Businesses that prioritize fulfillment accuracy not only reduce operational costs but also strengthen customer trust and brand loyalty. What Causes Fulfillment Errors? Most fulfillment errors can be traced back to process gaps rather than isolated mistakes. Inaccurate inventory records, manual data entry, inconsistent picking methods, poor warehouse organization, and insufficient employee training all increase the likelihood of errors. As businesses expand into multiple sales channels—including ecommerce, retail, wholesale, and marketplaces—the complexity of fulfillment grows. Without standardized workflows and real-time inventory visibility, even well-managed operations can experience declining accuracy. Identifying the root cause of fulfillment errors is the first step toward building a more reliable operation. How Can Warehouse Technology Improve Fulfillment Accuracy? Technology plays a critical role in reducing fulfillment errors by replacing manual processes with automated workflows and real-time visibility. A modern Warehouse Management System (WMS) helps ensure associates pick the correct products, maintain accurate inventory records, and track every stage of the fulfillment process. Barcode scanning further improves accuracy by verifying products before they are packed and shipped. Barrett Distribution utilizes a Tier 1 Warehouse Management System along with transportation management software, customer dashboards, and embedded analytics to provide customers with real-time visibility into inventory, orders, and operational performance. These tools help businesses make faster decisions while maintaining high levels of inventory accuracy. Why Are Standardized Warehouse Processes Important? Technology alone cannot eliminate fulfillment errors. Consistent operational processes are equally important. Standardized receiving, putaway, picking, packing, quality inspections, and shipping procedures help ensure every order is handled the same way regardless of volume or seasonality. Clear workflows also make employee training more effective and reduce the likelihood of human error. Experienced fulfillment providers continually evaluate their processes to identify opportunities for improvement, helping maintain consistent service levels as customer demand changes. How Does Employee Training Reduce Fulfillment Mistakes? Warehouse associates are essential to fulfillment accuracy. Comprehensive onboarding, ongoing training, and clear performance expectations help employees understand operational procedures while reinforcing quality standards. Regular coaching and continuous improvement initiatives can further reduce errors by addressing process issues before they become recurring problems. Creating a culture where accuracy is valued alongside productivity often leads to stronger long-term operational performance. Why Is Inventory Accuracy Essential? Accurate inventory is the foundation of successful order fulfillment. When inventory records don't match what's physically available, businesses risk overselling products, delaying shipments, or shipping incorrect items. Maintaining inventory accuracy through regular cycle counts, real-time inventory updates, and disciplined warehouse processes helps prevent these issues before they affect customers. Greater inventory visibility also allows businesses to make more informed purchasing, forecasting, and replenishment decisions. Can a 3PL Help Reduce Fulfillment Errors? For many businesses, partnering with an experienced third-party logistics provider is one of the most effective ways to improve fulfillment accuracy. A qualified 3PL combines proven warehouse processes, experienced operations teams, advanced technology, and continuous improvement programs to help reduce errors while supporting business growth. Barrett Distribution emphasizes operational excellence through standardized processes, quality management, technology investments, and continuous improvement initiatives designed to improve inventory accuracy and fulfillment performance. The company also supports omnichannel fulfillment, allowing businesses to manage both retail and direct-to-consumer orders through customized logistics solutions. How Can Businesses Continuously Improve Fulfillment Performance? Reducing fulfillment errors isn't a one-time project—it's an ongoing process. Leading organizations regularly monitor key performance indicators (KPIs), review error trends, and identify opportunities to improve warehouse operations. By analyzing fulfillment data and refining processes over time, businesses can maintain high accuracy even as order volumes increase. Working with a logistics partner that prioritizes continuous improvement can help companies adapt to changing customer expectations while maintaining consistent service quality. Frequently Asked Questions What is the most common cause of fulfillment errors? Common causes include inaccurate inventory records, manual processes, inconsistent warehouse procedures, and insufficient employee training. How does a Warehouse Management System reduce fulfillment errors? A Warehouse Management System improves inventory accuracy, guides warehouse associates through standardized workflows, and verifies products using barcode scanning to reduce picking and shipping mistakes. Can outsourcing fulfillment improve order accuracy? Yes. An experienced 3PL can provide standardized processes, advanced warehouse technology, and dedicated operations teams that help reduce fulfillment errors while supporting business growth. Barrett Distribution offers customized omnichannel fulfillment solutions designed to improve operational accuracy and efficiency. Why is inventory accuracy important for fulfillment? Accurate inventory helps prevent stock discrepancies, backorders, incorrect shipments, and delayed deliveries while improving customer satisfaction and operational efficiency.
Warehousing near Boston helps businesses reduce shipping costs, shorten delivery times across the Northeast, and improve overall supply chain efficiency. With access to major transportation networks and experienced third-party logistics (3PL) providers, Greater Boston is an ideal location for businesses looking to support both ecommerce and retail fulfillment. Key Takeaways Warehousing near Boston reduces shipping costs and speeds up deliveries across the Northeast. The region offers access to major highways, the Port of Boston, and Logan International Airport. Partnering with an experienced 3PL provides scalable fulfillment, advanced technology, and operational expertise to support business growth. Why Is Warehousing Near Boston a Strategic Advantage? For businesses serving customers throughout New England and the Northeast, warehouse location directly impacts delivery speed, transportation costs, and customer satisfaction. By positioning inventory closer to customers, companies can shorten transit times, lower shipping expenses, and create a more responsive supply chain. Greater Boston offers access to one of the country's largest consumer markets while serving as a central distribution hub for the Northeast, making it an ideal location for both retail and ecommerce fulfillment. How Does Warehousing Near Boston Reduce Shipping Costs? Transportation is one of the largest expenses in any supply chain. Storing inventory closer to customers allows businesses to reduce shipping distances, rely more on ground transportation, and minimize the need for expedited services. These efficiencies can significantly lower parcel shipping costs while improving delivery performance—especially for companies shipping high volumes of ecommerce orders. Why Is Boston a Strong Logistics Hub? Boston combines a strategic geographic location with robust transportation infrastructure. Major interstate highways, Logan International Airport, and the Port of Boston provide efficient access for both inbound freight and outbound distribution. This connectivity helps businesses move products quickly throughout New England while supporting domestic and international supply chains. Can a Boston Warehouse Support Both Retail and Ecommerce Fulfillment? Yes. Most businesses today serve multiple sales channels, from ecommerce websites and marketplaces to wholesale customers and retail stores. A capable 3PL should be able to manage all of these from a single fulfillment operation. Barrett Distribution specializes in omnichannel fulfillment, supporting both business-to-business retail distribution and direct-to-consumer ecommerce fulfillment through customized warehouse solutions. How Does Technology Improve Warehouse Operations? Modern fulfillment relies on technology to improve inventory accuracy, visibility, and efficiency. Barrett utilizes a Tier 1 Warehouse Management System (WMS), transportation management software, customer dashboards, and embedded analytics that provide customers with real-time insight into inventory, orders, and operational performance. These tools help businesses make informed decisions while maintaining accurate inventory and consistent service levels. Why Partner with an Experienced Boston 3PL? Choosing the right warehouse partner is just as important as choosing the right location. An experienced 3PL provides scalable warehouse space, trained operations teams, proven fulfillment processes, and continuous improvement initiatives that help businesses adapt as demand changes. Since 1941, Barrett Distribution has provided customized third-party logistics services to companies across industries including consumer products, apparel, food and beverage, health and beauty, retail, and ecommerce. With multiple facilities in the Greater Boston region, Barrett combines national scale with local expertise to help businesses strengthen their supply chains. Is Warehousing Near Boston Right for Your Business? If your customers are concentrated in New England or throughout the Northeast, warehousing near Boston can provide a measurable competitive advantage. Faster delivery times, lower transportation costs, and access to a strong logistics network all contribute to a more efficient supply chain. Whether you're expanding your ecommerce operation or optimizing retail distribution, a strategically located Boston warehouse can help position your business for long-term growth. Frequently Asked Questions What are the benefits of warehousing near Boston? Warehousing near Boston helps businesses reduce shipping costs, shorten delivery times, improve access to Northeast customers, and create a more efficient supply chain. Why is Boston a good location for a fulfillment center? Boston offers access to major highways, the Port of Boston, Logan International Airport, and one of the largest consumer markets in the Northeast, making it an excellent location for regional distribution. Can a Boston warehouse support both B2B and direct-to-consumer fulfillment? Yes. Many third-party logistics providers, including Barrett Distribution, support both retail distribution and direct-to-consumer ecommerce fulfillment from the same warehouse network. What industries benefit from warehousing near Boston? Industries including consumer packaged goods (CPG), apparel, health and beauty, food and beverage, retail, and ecommerce can all benefit from Boston's strategic location and transportation infrastructure. Barrett supports customers across these industries with customized logistics solutions.
In the logistics industry, speed is everything. Orders need to move quickly, customers expect accuracy, and warehouses often operate around the clock to keep supply chains moving. With that pace, employee training can sometimes become an afterthought—focused on getting new hires on the floor as quickly as possible rather than preparing them for long-term success. At Barrett Distribution, the philosophy is different. Training isn't simply part of onboarding—it's the foundation of the company's culture. From the moment a new employee joins Barrett, they're introduced to a clear vision for growth, continuous improvement, and career development. Rather than preparing employees for just today's job, Barrett invests in helping them build a future within the organization. "We're a strong advocate of promotion from within, and the only way to achieve that is through a dedicated training and development environment," says Judith Cantino , Barrett's Vice President of Human Resources. "Promotion-from-within is core to our culture and who we are, and it's introduced and reinforced from Day One of every colleague's New Employee Orientation." Why Training Matters More Than Ever The warehousing and logistics industry continues to face one of its biggest workforce challenges: employee retention. For many warehouse workers, the first week on the job follows a familiar pattern—a safety video, a quick tour of the facility, and then straight to the warehouse floor. While the goal is to get employees productive quickly, compressed onboarding often leaves new hires feeling underprepared. Industry turnover rates regularly range between 36% and 49% annually , significantly higher than many other industries. Much of that turnover happens during an employee's first few weeks, when inadequate training can lead to frustration, mistakes, and ultimately, resignation. Companies that invest in learning and development consistently see stronger employee engagement and retention. Barrett's turnover rate is significantly lower than the industry average, a result the company attributes in part to its long-term commitment to employee development. Training Begins on Day One Every Barrett employee starts with more than just operational instruction. New hires are introduced to the company's mission, values, and the principles that guide every department. Regardless of whether someone joins Operations, Customer Experience, IT, or another team, their development is built around shared concepts that shape Barrett's culture. "From Day One, employees are introduced to Barrett's vision and values," Cantino explains. "Every training program that follows is built around the same core concepts: Lean and Continuous Improvement, and One Call Resolution." By creating a consistent foundation across the organization, employees develop a shared understanding of how Barrett approaches customer service, operational excellence, and problem-solving. Turning Jobs Into Careers For Barrett, employee development isn't about checking a box during onboarding. It's about creating opportunities for long-term growth. The company believes that promoting from within strengthens both the workforce and the business. Employees already understand Barrett's culture, systems, and customer expectations, making transitions into new roles smoother while reducing the learning curve. "Promoting from within builds trust across teams, reduces training time, and saves money," says Cantino. "It shows people that they have a future here, which keeps good employees from leaving—and when people see a coworker move up, it motivates the whole team to work harder." She adds, "Promotion-from-within takes a job and turns it into a career." That philosophy is supported through specialized training programs, a dedicated learning management system, and development opportunities designed specifically for Barrett employees. Learning Doesn't Stop After Orientation Employee development continues well beyond a new hire's first weeks. Barrett offers compliance training, department-specific education, and specialized programs that help employees build both technical and leadership skills throughout their careers. Among those opportunities are the Always Better Champions Program , designed for supervisors and above at remote locations, and the Emerging Leader Program , which prepares high-potential employees for future leadership roles. Operations employees and Barrett's Centers of Excellence also have access to an English as a Second Language (ESL) program, while the company's Safety team provides OSHA training for leaders, equipment operators, and remote employees to help maintain a safe working environment. Operational excellence remains another major focus. Barrett's Operations Excellence (OPEX) team supports training across more than 120 operational skills, processes, and standard operating procedures. Meanwhile, the company's learning management system gives employees access to more than 60,000 courses from over 120 publishers , covering topics that range from leadership and project management to artificial intelligence, cybersecurity, communication, and professional development. The goal is simple: provide employees with the tools they need not only for their current role, but also for the next step in their careers. Preparing Employees for Every Customer No two Barrett customers operate exactly the same way. From consumer packaged goods and apparel to health and beauty, food and beverage, and ecommerce brands, every client has unique operational requirements. Rather than relying solely on general warehouse training, Barrett prepares employees using customer-specific procedures. "Employees learn Customer-Specific Standard Operating Procedures," Cantino says. "They're prepared for the exact requirements of the account they support—not just warehouse work in general." This customer-focused approach helps ensure employees understand the unique expectations of each operation, supporting both service quality and operational consistency. Investing in People to Better Serve Customers Training isn't just an internal initiative—it directly impacts the customer experience. Employees who understand warehouse processes, customer requirements, and Barrett's operational standards are better equipped to work accurately, solve problems, and respond to changing business needs. Continuous learning also supports Barrett's culture of Lean thinking and continuous improvement, helping teams identify opportunities to improve efficiency over time. While many organizations view training as a short-term expense, Barrett sees it as a long-term investment. As Cantino puts it, the company believes in preparing employees not just for the job they have today, but for the career they can build tomorrow. That investment benefits everyone—from employees looking to grow professionally to customers who rely on Barrett for consistent, high-quality logistics services.
