Order picking accuracy: How to improve this metric

Order picking accuracy has become a key priority in warehousing. In the age of e-commerce and on-demand delivery, efficiency depends not only on speed but also on the accuracy of order fulfillment. In this post, we take an in-depth look at order picking accuracy, explain how to measure the impact of this key performance indicator (KPI), and outline its benefits. We’ll also review best practices and technologies for improving this metric.

What is order picking accuracy?

Order picking accuracy refers to selecting the correct items from storage and minimizing mistakes throughout the fulfillment process. The goal is to ensure that every order reaches the customer exactly as requested, even for high-volume, fast-moving facilities. Reduced errors mean fewer complaints and less additional work associated with reverse logistics, including checking returns, sending replacement items, and managing incidents.

To achieve optimal accuracy levels, companies put in place procedures that verify each stage of order fulfillment. For example, by identifying items with barcodes or RFID tags and recording every movement, they can confirm that the correct goods were shipped. Detailed information also strengthens customer confidence.

Many of these checks are performed using a warehouse management system (WMS), which records every movement in real time and generates KPIs. One of the most important is order picking accuracy, which measures the percentage of orders filled correctly and assesses the quality of the fulfillment process.

Benefits of increasing order picking accuracy

Accurate order fulfillment has a positive effect across the supply chain:

• More reliable inventory records. Accurate picking keeps physical stock aligned with the information in the WMS. This simplifies replenishment planning and helps resolve inventory discrepancies.
• Lower costs. Fewer errors mean less additional work, such as reshipping orders. Companies can make better use of warehouse resources and keep expenses in check.
• Fewer returns and complaints. Correctly filled orders help prevent issues. As a result, businesses spend less time correcting mistakes and can provide superior service.
• Higher productivity. Without the need to correct errors, warehouse associates can focus on filling new orders. The facility can handle more work without adding staff or other resources.
• A better customer experience. Receiving the correct merchandise in full and within the expected time frame boosts satisfaction and strengthens trust in the company. Over time, this experience fosters customer loyalty.

How is order picking accuracy measured?

The order picking accuracy rate shows the percentage of orders picked correctly during a given period.

High-performing warehouses may still experience occasional picking errors, so it’s essential to measure the process’s accuracy and strive to maintain it. Even a low error rate can translate into a significant number of incorrect orders when activity volumes are high. For this reason, it’s critical to monitor this KPI and keep it as close to 100% as possible.

The most common formula for measuring order picking accuracy is:

A high result means that most orders are completed without mistakes, while a low value points to recurring issues.

Depending on a company’s needs, the metric can also be calculated based on picked order lines or units rather than the complete order. This provides a more detailed view of where errors occur and supports the adoption of corrective measures.

How to improve order picking accuracy

Achieving a high level of accuracy calls for a well-organized facility and technologies that record and verify each step. Below, we review some best practices for minimizing errors.

Standardize processes

Defining procedures helps associates follow the same sequence every time. They should receive clear instructions on how to locate, identify, and validate items, as well as what to do when an item is missing. Ongoing training is also crucial for maintaining quality across warehouse operations.

Integrate identification technologies

Barcodes and RFID tags confirm that the item picked matches the one requested. By validating the SKU, quantity, or lot during picking, these technologies help prevent mistakes while enabling traceability.

Implement a WMS

A warehouse management system organizes picking tasks and directs associates to the appropriate locations. At each step, it verifies that the correct item has been picked and flags any discrepancies before the order is confirmed.

Use picking guidance systems

Solutions such as pick-to-light, put-to-light, and pick-by-voice tell associates which item to pick and where to find it. Visual or voice prompts remove uncertainty from the process. They support more accurate order fulfillment, particularly in facilities with a large number of SKUs.

Automate picking

Goods-to-person automation solutions bring items to associates so they can fill orders at stationary workstations. For instance, Interlake Mecalux’s mini-load system (AS/RS for boxes) and Shuttle System eliminate the need to travel. At high-performance pick stations, associates receive instructions on which items to pick. Together, these solutions minimize picking errors.

Success stories in order picking accuracy

Several companies have minimized order fulfillment errors by introducing Mecalux’s warehouse management system and automation solutions. Here are some examples:

• Browne (Canada). The kitchenware company fills up to 120 orders a day for customers in Canada and the US. Easy WMS organizes tasks and prioritizes shipments based on carriers’ scheduled pickup times. “Thanks to Easy WMS, we’ve boosted productivity. Each associate can handle up to 150 order lines per hour with more than 99% accuracy,” says Browne.
• Panabad (Spain). Order fulfillment begins at 10:00 p.m. to enable overnight distribution of frozen products from the company’s bakery in Barcelona. Easy WMS calculates the most efficient routes to limit travel inside the warehouse, kept at -4 °F. “With Mecalux’s digital tool, we’ve increased accuracy and minimized the possibility of errors,” says Panabad.
• Jung Logistique (France). This 3PL uses two picking stations equipped with put-to-light systems to handle around 500 orders a day. Associates follow Easy WMS’s instructions to place items in the correct locations and quantities. According to the 3PL, “this system raises order picking quality, ensuring greater accuracy and customer satisfaction.”
• Bright Junior Media (Poland). Easy WMS coordinates both inventory replenishment and the fulfillment of approximately 1,500 orders a month for toy stores throughout Poland. By coordinating these processes, the system streamlines picking and eliminates errors. “We’ve optimized order fulfillment to achieve maximum accuracy with every shipment,” the company says.

Accuracy: A constant order picking goal

Order fulfillment accuracy depends on people, processes, and technology working in sync. Tracking performance with KPIs such as order picking accuracy helps identify areas for improvement and assess the impact of adopted measures. As customer expectations rise, digitalization and automation are becoming vital tools for keeping picking aligned with business needs.

Before introducing measures to increase the accuracy of the process, keep the following points in mind:

• Review order picking accuracy regularly to spot errors and track changes over time.
• Standardize picking so all associates follow consistent procedures.
• Implement identification technologies, guidance systems, and automation to minimize mistakes during fulfillment.
• Use a warehouse management system, such as Interlake Mecalux’s Easy WMS, to coordinate picking, validate each step, and enhance accuracy.