Common Putaway Mistakes and How to Avoid Them

Introduction

Putaway mistakes can quietly erode warehouse efficiency and customer satisfaction. For beginners, recognizing typical errors and learning straightforward fixes can prevent costly disruptions. This guide lists common putaway mistakes, explains why they matter, and offers practical solutions that are easy to implement.

Mistake 1: No clear slotting strategy

Problem: Storing SKUs arbitrarily or letting staff choose locations at random leads to long travel times and confusion.

Solution: Implement a basic slotting strategy such as ABC classification. Place high-velocity items in accessible areas, group similar items together, and document rules clearly in your WMS or on physical labels.

Mistake 2: Poor or inconsistent labeling

Problem: Undefined or damaged labels cause misplacements and slow down both putaway and picking.

Solution: Standardize label formats and location codes, use durable label materials, and scan locations during putaway to confirm placement. Regularly inspect and replace worn labels.

Mistake 3: Relying on manual processes without a WMS

Problem: Manual spreadsheets and memory are error-prone, especially as SKU counts grow.

Solution: Start with a basic WMS or inventory app that enforces putaway rules and records locations in real time. Even low-cost mobile scanning solutions can dramatically reduce mistakes.

Mistake 4: Not managing exceptions

Problem: Damaged goods, overages, or returns get mixed into general inventory when there is no quarantine area, causing quality issues and returns handling problems.

Solution: Create a quarantine or inspection zone. Define rules for damaged items, returns, and supplier discrepancies and train staff to follow them.

Mistake 5: Overfilling aisles and staging areas

Problem: Congested aisles slow down movement and increase the risk of accidents.

Solution: Maintain clear staging areas sized for expected inbound volumes. Schedule inbound appointments and use temporary overflow staging or cross-dock areas for high-volume days.

Mistake 6: Ignoring ergonomics and safety

Problem: Placing heavy items in awkward positions increases injury risk and slows operations.

Solution: Store heavy or frequently handled items at waist height when possible, use mechanical aids, and enforce safe lifting procedures.

Mistake 7: Failure to update inventory immediately

Problem: Delayed updates lead to mismatches between the system and physical inventory, causing picking errors and stock discrepancies.

Solution: Require scanning at the point of putaway confirmation. If network constraints exist, use mobile devices that sync when connected and track offline changes clearly.

Mistake 8: Not training staff or allowing informal shortcuts

Problem: Lack of consistent training leads to ad hoc practices and shortcuts that create long-term inefficiencies.

Solution: Provide clear onboarding and regular refresh training. Use simple job aids posted in work areas and encourage feedback from the team for continuous improvement.

Mistake 9: Neglecting measurement and continuous improvement

Problem: Without KPIs, you won’t know where putaway is failing or improving.

Solution: Track basic metrics such as putaway time, accuracy, and travel distance. Review results weekly or monthly and test small changes to find gains.

Mistake 10: Overcomplicating early-stage systems

Problem: Implementing complex automation or overly strict rules before processes are stable can backfire. Solution: Start with simple, well-documented rules and a basic system. As you collect data and refine operations, gradually introduce automation or more advanced WMS features.

Quick checklist to avoid common mistakes

• Establish an ABC slotting plan and update it periodically.
• Standardize and maintain location labels and product barcodes.
• Use scanning technology to confirm putaway in real time.
• Designate quarantine and staging areas for exceptions.
• Measure putaway KPIs and review them regularly.
• Train staff and encourage process feedback.
• Start simple and iterate based on data.

Real-world example

A midsize retailer experienced frequent picking errors after moving into a larger facility. The problem was traced to inconsistent putaway: items were placed wherever space was available and not recorded properly. The retailer implemented basic slotting for top-selling SKUs, introduced barcode scanning at putaway, and trained staff on the new rules. Within two months, picking accuracy improved substantially and order fulfillment times decreased.

Conclusion

Putaway mistakes are common but largely preventable. Focus on basic slotting, reliable labeling, real-time system updates, and training. By addressing these fundamentals, even small warehouses can eliminate many sources of error and unlock meaningful productivity improvements.