Running a smooth and efficient warehouse isn’t always straightforward. It takes a combination of smart processes, good staff, the correct equipment, and a focus on safety to keep everything on track. Unfortunately, some common mistakes continue to plague operations of all sizes. Here are five key errors every warehouse operative should avoid at all costs.
Too Much Inventory
It’s tempting to stockpile goods, especially when large orders are expected and suppliers offer discounts on bulk purchases. However, overfilling your warehouse with excess inventory ties up valuable cash and space. It can also slow down operations, making it harder for workers to navigate the warehouse safely and efficiently.
Instead, adopting a lean approach with just-in-time stock replenishment helps keep things flowing smoothly and reduces waste. Reliable pallet trucks can handle frequent restocking with ease, keeping goods moving without bottlenecks.
Poorly Planned Picking Paths
Failing to plan – or doing it badly – is planning to fail. Poorly planned picking paths waste time and energy; far more than it takes to optimise them! Workers end up covering unnecessary ground, which hurts productivity while increasing the risk of fatigue. Efficient picking routes allow staff to retrieve goods swiftly and safely.
Investing in heavy-duty manual handling equipment makes transporting large orders or heavy items along streamlined routes quicker and less physically demanding.
Outdated Processes
Clinging to paper-based systems is a surprisingly common pitfall. Paperwork slows operations, increases errors, and makes it harder to track stock accurately. Switching to digital systems is far more efficient and greatly reduces the risk of misplaced records, so that workers can easily keep pace with faster, more accurate workflows, cutting delays and errors.
Overlooking Safety
Health and safety shouldn’t be an afterthought. Overworked or poorly equipped staff are at risk of injury, especially in busy warehouses handling heavy loads. Strains, slips, and even more serious accidents can happen in a flash. Ensuring staff are properly trained and have access to quality manual handling tools, like Midland’s heavy-duty pallet trucks with ergonomic handles and smooth rollers, makes a real difference.
Neglecting Staff Wellbeing
The pressure to meet tighter targets and budgets is rising, but pushing workers too hard risks burnout, excessive strain and mistakes that can be costly – or even fatal. It’s essential to invest in both people and equipment to support a healthy, productive workplace.
Phil Chesworth, Managing Director at Pallet Trucks UK, puts it well. He explains, “In warehousing, looking after is good business and, most of all, the only right thing to do. Providing the right tools for the job helps staff work more safely, reducing downtime and keeping morale high.”