Order accuracy is one of the most important metrics in retail and ecommerce. When orders are picked and shipped correctly, customers receive what they expect, returns decrease, and operational costs stay low. When order accuracy drops, the impact spreads across the entire supply chain: higher return rates, lost sales, customer complaints, and inefficient warehouse operations.
A Warehouse Management System (WMS) plays a key role in improving order accuracy. By digitizing workflows, reducing manual steps, and improving visibility, a WMS helps retailers eliminate the most common causes of fulfillment errors.
This article explains why order accuracy matters, how errors occur, and how a WMS helps eliminate those errors and strengthen operational performance.
Table of Contents
- What Is Order Accuracy
- Why Order Accuracy Matters
- Common Causes of Order Errors
- How WMS Reduces Warehouse and Fulfillment Errors
- Best Practices for Improving Order Accuracy
- Conclusion
1. What Is Order Accuracy
Order accuracy measures how often a business ships the correct items, quantities, and configurations to customers. High order accuracy means shipments match customer expectations. Low order accuracy leads to mis-picks, wrong quantities, incorrect SKUs, missing items, or packaging mistakes.
A Warehouse Management System provides structured processes and data-driven workflows that reduce these mistakes and improve fulfillment consistency.
2. Why Order Accuracy Matters
Order accuracy affects several critical business outcomes:
- Customer satisfaction: Customers expect accurate and reliable delivery. Incorrect orders quickly damage brand trust.
- Return costs: Every incorrect shipment leads to additional costs for reverse logistics, repacking, and restocking.
- Marketplace performance: On platforms like Shopee, Lazada, and TikTok Shop, accuracy affects seller ratings and penalties.
- Operational efficiency: Errors slow down warehouse operations, require rework, and disrupt workflow planning.
- Profitability: Fewer mistakes mean lower cost per order and higher operational margins.
As retailers scale, manual processes struggle to maintain accuracy. A WMS becomes essential for achieving stable, reliable performance.
3. Common Causes of Order Errors
Order errors often come from manual, unstructured, or outdated warehouse processes. The most common causes include:
3.1 Manual Picking Errors
When pickers rely on paper lists or memory, mistakes in selecting SKUs are more likely.
3.2 Mislabelled or Misplaced Inventory
Incorrect or outdated shelf labels lead warehouse staff to the wrong items.
3.3 Poor Inventory Visibility
If stock data is inaccurate, pickers may select incorrect alternatives or substitute items without authorization.
3.4 Incomplete or Unclear Workflows
Without structured steps, different team members may follow different processes, increasing inconsistency.
3.5 High SKU Volume
Large assortments make it harder to pick accurately without system-driven guidance.
3.6 Human Fatigue and Peak Season Pressure
During high-volume periods, manual work becomes more error-prone.
These challenges show why technology-driven workflows are necessary.
4. How WMS Reduces Warehouse and Fulfillment Errors
A Warehouse Management System reduces the root causes of inaccuracies through automation, real-time data, and guided workflows.
4.1 Digital and Guided Picking
Instead of paper pick lists, a WMS provides digital pick instructions with item images, bin locations, and optimized pick paths. This reduces confusion and ensures the correct items are picked.
What this solves:
- Mis-picks
- Wrong item selection
- Incorrect product substitutions
4.2 Barcode Scanning for Verification
WMS workflows often include mandatory barcode or QR code scanning at picking, packing, and dispatch stages. This adds a verification layer that catches errors before they leave the warehouse.
What this solves:
- Incorrect SKUs
- Wrong quantities
- Packaging mistakes
4.3 Real-Time Inventory Accuracy
A WMS updates stock levels in real time as items are received, moved, picked, or returned. Accurate data prevents pickers from selecting unavailable or incorrect items.
What this solves:
- Picking from the wrong location
- Stockouts caused by manual updates
- Substituting items without authorization
4.4 Location Management and Slotting Optimization
WMS organizes storage locations and guides putaway to ensure that items are stored systematically.
What this solves:
- Misplaced inventory
- Confusion caused by inconsistent storage
- Inefficient pick paths
4.5 Automated Order Routing and Prioritization
A WMS helps determine the correct warehouse or picking area for each order. This reduces decision-making errors and supports fulfillment efficiency.
What this solves:
- Orders picked from the wrong zone
- Delays caused by manual routing decisions
4.6 Quality Control Checks
Most WMS workflows are designed to include a final QC step before dispatch. Staff verify the order content through scanning or system prompts.
What this solves:
- Wrong item shipped
- Missing items
- Incorrect bundles or kits
4.7 Reduced Manual Work and Less Human Error
By automating repetitive tasks and providing step-by-step workflows, a WMS reduces the cognitive load on staff, especially during peak season.
What this solves:
- Errors caused by fatigue
- Mistakes during high-volume shifts
5. Best Practices for Improving Order Accuracy
Even with the right system, businesses must adopt operational best practices to maximize accuracy.
5.1 Implement System-Based Picking and Verification
Use barcode scanning and mandatory system checks to eliminate manual confirmation steps.
5.2 Maintain Accurate Inventory Records
Cycle counts and regular audits ensure physical stock matches system data.
5.3 Optimize Warehouse Layout
Group fast-moving products near packing stations and organize SKUs logically to reduce confusion.
5.4 Train Staff Regularly
Clear operating procedures and continuous training help reduce avoidable errors.
5.5 Integrate WMS with OMS
Connecting WMS with the Order Management System ensures consistent, real-time order and inventory flow.
5.6 Monitor Key Accuracy KPIs
Track mis-picks, return reasons, cycle count results, and warehouse error rates to identify improvement areas.
6. Conclusion
Order accuracy is a critical performance driver for retail and ecommerce operations. Incorrect shipments create immediate customer dissatisfaction, increase returns, and raise operational costs. A Warehouse Management System provides the structure, automation, and visibility needed to eliminate common fulfillment errors and ensure reliable order delivery.
As retailers scale across channels and warehouses, adopting a WMS becomes essential for maintaining accuracy and operational stability.
To learn how Opollo helps retailers improve warehouse accuracy and streamline order fulfillment, contact our team.
