Product labelling and load picking
An error that leaves the warehouse comes back as a return. We attacked it at the source: the check itself.
The problem
Loading and delivery errors. A wrong item on a truck does not end at the warehouse: it comes back as a return, a repeated freight cost, rework for production planning and friction with the customer.
My contribution
- Implemented the product labelling system.
- Implemented the load picking project.
- Trained the teams on the new checking routine.
- Followed the rollout until the routine held on its own in the operation.
Outcome
A sharp drop in loading and delivery errors, with checking no longer depending on the operator’s memory.
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Context
An industrial operation across three plants (SP, PR and PE), where load checking depended on human reading and on the operator’s accumulated knowledge.
A shipping error is one of the few IT-adjacent problems whose cost shows up in full on the company’s bottom line: freight, returns, rework and customer credit. And it is typically treated as carelessness — which guarantees it comes back.
The approach was to take the check out of the operator’s memory and put it into the process. With product labelling and structured picking, verification gains a step you can actually audit: the item leaving is the item that was ordered, and that is confirmed before the truck closes.
The least technical part mattered most. Shipping works against the clock, and any new step that slows loading down gets abandoned on the first hard day. That is why training and rollout follow-up were part of the project scope: a solution only really exists once it survives the day nobody has any time.
Lessons learned
- A shop-floor project is not delivered in a staging environment: if the shipping team does not understand the flow, the routine goes back to paper in the first week under pressure.
- Training and post-rollout follow-up are not the final phase of the project — they are part of the solution.
- Physical identification is process control: where there is a label there is traceability, and where there is traceability the error has an address.