Common Pick Face Mistakes and How to Avoid Them

Even experienced warehouses make pick-face mistakes that cost time and money. For beginners, recognizing these pitfalls early helps you avoid simple but costly errors. Below are the most frequent pick-face mistakes and practical ways to prevent them.

Mistake 1: Poor slotting (placing SKUs in the wrong spots)

Placing slow-moving SKUs on prime pick faces or scattering fast-moving SKUs across multiple distant locations increases picker travel time. Remedy this by doing an ABC analysis and slotting A-items close to packing areas at comfortable heights. Regularly review slotting data and adjust as demand patterns change.

Mistake 2: Inconsistent or unclear labeling

When labels are small, missing, or inconsistent, pickers waste time verifying SKUs or make wrong picks. Standardize label format (SKU, description, barcode, quantity per location) and keep labels oriented to face the aisle. Use durable materials so labels don’t peel off in humid or high-traffic areas.

Mistake 3: No buffer or poor replenishment process

If pick faces run out mid-shift, pickers stop work and wait for replenishment, harming throughput. Establish minimum/maximum levels and automate replenishment tasks in your WMS. Maintain small buffer locations next to pick faces to allow quick top-ups without interfering with picking flows.

Mistake 4: Overcrowded pick faces

Stuffing too many SKUs into one pick face or stacking items awkwardly causes mispicks and slow retrieval. Keep pick faces tidy and avoid excessive depth. If a single location holds more than one SKU, clearly separate and label compartments to prevent confusion.

Mistake 5: Ignoring ergonomics

Placing high-demand SKUs at floor level or on the topmost shelves leads to fatigue and injuries. Position heavy or bulky items at knuckle height and rotate tasks or use mechanical aids when repetitive lifting is unavoidable. Ergonomic improvements both increase speed and reduce absenteeism

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Mistake 6: Not using data to drive decisions

Decisions based on intuition or legacy layouts often underperform. Use picking data—pick frequency, picks per order, travel paths—to inform slotting, pick-face sizing, and replenishment. Even simple spreadsheets showing frequency by SKU provide a big advantage.

Mistake 7: Poor training and unclear SOPs

When new or temporary staff receive inconsistent training, error rates climb. Create short, visual SOPs for pick-face procedures and run quick on-the-job training sessions. Checklists and mentor systems help maintain consistency during peak times.

Mistake 8: Not planning for seasonality or promotions

Static pick-face layouts that don’t account for seasonal spikes lead to bottlenecks. Before promotions or peak seasons, temporarily reposition promotional SKUs to prime pick faces and increase buffer levels. Revert after the peak to keep long-term efficiency.

Mistake 9: Ignoring small but frequent issues

Small friction points—like a smeared barcode or a partially blocked aisle—compound into significant delays. Encourage pickers to report issues and maintain a fast-response process to fix them. Regular housekeeping rounds prevent small issues from becoming systemic.

Mistake 10: Over-automating without fundamentals

Investing in pick-to-light or conveyors without first stabilizing pick-face labeling, slotting, and replenishment usually fails. Ensure foundational practices are solid before adding automation so the systems can perform as intended.

Practical checklist to avoid these mistakes

• Run an ABC analysis and implement slotting changes every quarter.
• Create and enforce standardized pick-face labels and orientations.
• Set replenishment triggers in your WMS and maintain buffer locations.
• Train staff on SOPs and run short refreshers before peak periods.
• Monitor picking KPIs and act on anomalies quickly.

By being aware of these common pitfalls, beginners can build resilient pick-face systems that scale. Fix the basics first—good slotting, clear labeling, reliable replenishment—and your pick faces will support faster, more accurate fulfillment with fewer headaches.