How Can a Warehouse Cut Picking and Labelling Errors?
In short
Scan at every handoff and print labels from system data. Rugged handhelds and scanners confirm each item at goods-in, put-away, picking and dispatch; BarTender prints carton and pallet labels from your WMS; matched labels and ribbons keep them readable; and SOTI keeps the devices and printers managed centrally.
A warehouse runs on handoffs. Goods arrive, are put away, are picked, packed and sent. Every handoff is a chance for the physical stock and the system to drift apart.
This article looks at where errors start in warehouse and logistics operations, and at the scanning, labelling and device management that address them.
Where do errors creep into a warehouse?
Most errors are small, and they add up:
- Goods-in: a delivery is counted by eye and keyed in later, with the wrong quantity or item.
- Put-away: stock goes to a different location from the one the system expects.
- Picking: a similar-looking item is picked from the next bin.
- Labelling: a carton label is hand-written, printed from the wrong record or too faint to scan.
- Dispatch: a parcel leaves without being confirmed against the order.
What these have in common is a step where a person, not a scan, confirms what happened.
Why scan at every handoff?
A scan turns a guess into a record. When staff scan the item and the location at each step, the system knows what moved, where and when.
Scanning also catches mistakes at the moment they happen. If a picker scans the wrong item, the handheld can say so before the carton is sealed, not after the customer calls.
That only works if the scanning device runs an app tied to your warehouse system. Where an off-the-shelf app does not fit your process, our software development team writes custom Android apps for Zebra and Honeywell handhelds.
What does a scanned pick look like step by step?
A simple picking flow on a handheld shows how the checks fit in:
- The picker opens the next order on the handheld and is sent to the first location.
- They scan the location label to confirm they are at the right bin.
- They scan each item; the app checks it against the order and the quantity.
- A wrong item or quantity is flagged on the screen straight away.
- When the order is complete, the carton label prints from the order record.
Each scan replaces a moment where someone would otherwise rely on memory.
Which scanning devices suit which jobs?
Different jobs call for different tools. Our mobile computers page describes the main types:
| Device | Suits |
|---|---|
| Handheld mobile computer | Picking, counting and goods-in, one-handed |
| Wearable mobile computer | Hands-free sorting and packing |
| Vehicle-mounted computer | Forklifts and freight vehicles |
| Handheld or fixed barcode scanner | Packing benches, dispatch and conveyors |
Warehouses are hard on equipment, so check the vendor’s drop and sealing ratings. For example, Honeywell’s datasheet for the Xenon XP 1950g states that it withstands 50 drops from 1.8 m to concrete and is sealed to IP41.
How do you get labels right first time?
A label is data in physical form. It should come from the system, not be typed at the printer.
- Print from system data. BarTender states that it can integrate with ERP, WMS and MES systems using REST APIs, file drop or no-code builders. A label job can then be triggered when goods are received or an order is packed.
- Use the right printer. Desktop printers suit low to medium volumes, industrial printers suit high-volume work, and mobile printers suit printing at the rack. See our barcode printers.
- Match labels and ribbons. Thermal transfer labels need the right ribbon, whether wax, wax/resin or resin, for the surface and conditions. Our consumables page covers the options.
BarTender also supports more than 12,000 printer drivers, so it can usually work with the printers you already have. If you need labels in volume without running printers yourself, our label printing service can print them for you.
How do you keep handhelds and printers running?
A warehouse with dozens of handhelds cannot configure them one by one. SOTI MobiControl sets up, locks down and updates devices from one console, and lets several shifts share one pool of devices.
Printers can be managed the same way. SOTI states that SOTI Connect manages mobile and industrial printers from makers including Zebra, SATO, TSC Auto ID, Brother and Epson, with firmware updates, dashboards and device logs.
When a device does fail, local maintenance and support keeps one faulty scanner from stalling a shift.
What about the warehouse’s own equipment?
Stock is only half of what a warehouse holds. Handhelds, printers, tools and other equipment need tracking too.
ZOVYX, our own asset management system, tracks assets across branches and locations with RFID and barcode. It handles check-out and return, maintenance schedules and transfer orders between branches with pick lists and scanning. ZOVYX lists warehouses and retail among the teams it is built for.
What should you check before choosing equipment?
- Which system is the master? Your WMS or ERP should own the data the devices read and write.
- Which steps are unscanned today? Start where errors cost most.
- What environment? Cold rooms, dust and drops change which devices will last.
- Which labels? Size, material and how long they must stay readable.
- Who supports it? Devices, printers and the software link all need an owner.
How does Techcon Solution help warehouses?
Our warehouse & logistics solution brings together rugged mobile computers, barcode scanners, BarTender, barcode printers and matched consumables. We build the software link to your WMS or ERP, write handheld apps where needed, supply and set up SOTI, and support it all locally in Hong Kong.
To see how the pieces connect, read how to connect ESL, scanners and printers to your POS or ERP, or get in touch to discuss your operation.
Frequently asked questions
Where do most warehouse errors start?
At the handoffs, where goods change hands or places. Goods-in, put-away, picking and dispatch are where an unscanned item or a hand-written label turns into a wrong shipment.
Which mobile computer suits warehouse work?
Handheld computers suit most picking and counting. Wearable computers suit hands-free sorting and packing, and vehicle-mount computers suit forklifts and freight vehicles.
How rugged does a warehouse scanner need to be?
Check the vendor datasheet for drop and sealing ratings. For example, Honeywell's datasheet for the Xenon XP 1950g states it withstands 50 drops from 1.8 m to concrete and is sealed to IP41.
Can labels print automatically from our WMS?
Yes. BarTender states that it can integrate with business systems such as ERP, WMS and MES, using REST APIs, file drop or no-code builders.
Can one system manage our handhelds and our label printers?
Yes. SOTI MobiControl manages the handhelds, and SOTI Connect manages mobile and industrial printers from makers including Zebra, SATO, TSC Auto ID, Brother and Epson.
Source: SOTI Connect
What if we need labels but do not want to run printers ourselves?
Techcon Solution offers bureau label printing, using the same barcode printers and consumables we sell, for customers who need labels in volume without owning the printing hardware.
