Author: Jason Martin
Reviewed by: Supply Chain Solutions Lead
Last updated: October 29, 2025
Executive TLDR
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Accuracy pays twice, fewer errors and lower costs.
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Lock barcodes, clean locations, and scan at pick and pack to stop mispicks.
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Use ASNs and a 1 to 3 day dock to stock target so inventory is sellable fast.
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Right size packaging and rate shop each label to reduce DIM and freight spend.
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FEFO with lot and expiry keeps consumables compliant while moving quickly.
Want a practical accuracy playbook for your brand — talk to Product Fulfillment Solutions.
Table of contents
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Why accuracy drives profit
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Where accuracy breaks
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The five step accuracy system
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Controls for dated and regulated goods
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Cost levers tied to accuracy
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Your 30 day rollout plan
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Why Product Fulfillment Solutions
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FAQ
Why accuracy drives profit
Every error is a double hit, you pay to ship the wrong thing and pay again to fix it. Tight accuracy lowers rework, refunds, and support tickets. Orders leave on time, customers trust your brand, and cost per order drops.
Where accuracy breaks
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Messy receiving: No ASN, wrong counts, slow putaway.
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Look alike SKUs: Similar sizes or colors stored together.
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No scan at pack: One missed check creates swaps and returns.
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Oversized packaging: DIM weight charges hide as “shipping costs.”
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Split inventory too early: Thin safety stock raises backorders and mispicks.
The five step accuracy system
1) Clean data and one barcode per sellable unit
Build a single product master with barcode, dimensions, weight, case and inner details, and hazard flags. Post unit, carton, and pallet label placement rules. Keep this visible with real time information and standardize under 3PL fulfillment.
2) ASN discipline and dock scheduling
Send a complete ASN for every inbound. Book dock appointments and target 1 to 3 day dock to stock. Match carton contents at the door, count, quality check, then move to putaway. If space is tight, expand with warehousing and storage solutions.
3) Location logic and slotting by velocity
Use large, high contrast bin IDs. Keep fast movers near pack. Separate look alikes. Audit a few bins daily. As orders scale, fold this into ecommerce fulfillment services to keep rules consistent.
4) Scan at pick and scan at pack
Batch single line orders, cluster pick multi line, but always scan. Add a second scan at pack for risky items. Keep a small exception lane beside pack so relabel or rebag never stops the main line. See pick and pack services.
5) Packaging matrix and label timing
Post a simple matrix by product family, which mailer or carton to use. Print the carrier label after the final scan at pack. Rate shop every label with discounted shipping rates to keep speed and margin together.
Controls for dated and regulated goods
If you sell supplements, vitamins, cosmetics, or other consumables, accuracy must include freshness.
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Capture lot and expiry at receiving.
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Enforce FEFO at pick so older inventory moves first.
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Flag locations that require lot picks.
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For sets and subscriptions, include component lots on build sheets via kitting assembly services.
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Quarantine suspect returns and document destruction rules.
For category depth, review health and wellness fulfillment services.
Cost levers tied to accuracy
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Right size packaging: Cuts DIM weight and damage.
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Centralized inventory: A Cincinnati hub reaches most buyers in 1 to 3 days by ground while keeping one clean pool.
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Rate shopping: Mix national and regional carriers to hit promised dates at lower cost.
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Returns flow: Separate returns from outbound, triage fast, restock good units quickly.
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Exception lanes: Small relabel or rebag zones keep the main path moving.
Your 30 day rollout plan
Week 1, data and labels
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One product master with barcode, dimensions, weights, case packs, hazard flags.
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Unit, inner, carton, and pallet label templates.
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Post the packaging matrix at every pack bench.
Week 2, inbound discipline
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Lock ASN format and book dock times.
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Post a receiving checklist.
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Set and report 1 to 3 day dock to stock.
Week 3, floor design and scans
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Slot fast movers near pack.
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Print large bin IDs and separate look alikes.
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Turn on scan at pick and a second scan at pack.
Week 4, pilot and tune
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Pilot with the top 20 percent SKUs for one week.
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Measure order accuracy, handling time, billable vs actual weight, on time ship rate, and cost per order.
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Fix outliers. Roll learning to the next tier.
Why Product Fulfillment Solutions
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Central U.S. hub in Cincinnati for fast, affordable ground coverage.
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Barcode first receiving aligned to your ASN for predictable dock to stock speed.
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FEFO and lot or expiry control tailored for consumables.
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Pick and pack standards with scan at pack and a practical packaging matrix.
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Small parcel optimization with multi carrier rate shopping.
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Retail and marketplace readiness with simple label templates and EDI solutions and connections.
FAQ
What accuracy rate should we aim for
99.7 percent or better. Scan at pick and pack, separate look alikes, and audit a few bins daily.
Will scanning slow my team
No. It speeds troubleshooting and prevents rework. The time you save on fewer errors outweighs the scan.
Do I need multiple warehouses to improve accuracy
Start centralized. Accuracy rises when data and training live in one place. Add nodes only when transit savings beat the extra complexity.
How do I reduce DIM charges
Use the packaging matrix to right size every order. Recheck your top SKUs quarterly as packaging or demand changes.
How fast should new inventory go live
With clean ASNs and booked docks, target 1 to 3 days from truck to sellable stock.