Most errors begin upstream
Wrong-item shipments usually start before a picker reaches the aisle. Poor task setup, weak item identification, or unlogged overflow locations make errors more likely long before the tote is filled.
Protect location discipline
Lean teams can survive many operational imperfections, but they cannot survive uncertainty about where inventory really lives. Temporary moves need visible markers and quick cleanup or the floor will drift away from the system.
Give pickers a clear exception path
When a picker finds a short pick, damaged unit, or mismatch, the next step should be obvious. A simple pause-note-escalate rule prevents whispered workarounds that later become customer-facing mistakes.
Review misses by source
Count errors, but also classify them. If the same root causes keep showing up in labels, batching, or overflow handling, the team can fix the system instead of blaming the last person who touched the order.