{"id":9080,"date":"2026-05-23T07:23:12","date_gmt":"2026-05-23T05:23:12","guid":{"rendered":"https:\/\/www.balea.com\/non-classe\/the-true-cost-of-an-order-picking-error\/"},"modified":"2026-09-03T15:46:11","modified_gmt":"2026-09-03T13:46:11","slug":"the-true-cost-of-an-order-picking-error","status":"publish","type":"post","link":"https:\/\/www.balea.com\/en\/blog\/the-true-cost-of-an-order-picking-error\/","title":{"rendered":"The True Cost of an Order Picking Error"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"9080\" class=\"elementor elementor-9080 elementor-3431\" data-elementor-post-type=\"post\">\n\t\t\t\t<div class=\"elementor-element elementor-element-34b2014 e-flex e-con-boxed e-con e-parent\" data-id=\"34b2014\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t<div class=\"elementor-element elementor-element-e1f04ed e-con-full e-flex e-con e-child\" data-id=\"e1f04ed\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" class=\"e-image-base e-d8483e9-e1714f2\" data-interaction-id=\"d8483e9\" data-e-type=\"widget\" data-id=\"d8483e9\" id=\"9078\" src=\"https:\/\/www.balea.com\/wp-content\/uploads\/2026\/05\/encart-1-v02-1.jpg\" width=\"1370\" height=\"1121\" srcset=\"https:\/\/www.balea.com\/wp-content\/uploads\/2026\/05\/encart-1-v02-1.jpg 1370w, https:\/\/www.balea.com\/wp-content\/uploads\/2026\/05\/encart-1-v02-1-1080x884.jpg 1080w, https:\/\/www.balea.com\/wp-content\/uploads\/2026\/05\/encart-1-v02-1-1320x1080.jpg 1320w\" alt=\"\"\/>\t\t<div class=\"elementor-element elementor-element-765363f e-con-full e-flex e-con e-child\" data-id=\"765363f\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-5fe9287 elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"5fe9287\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">The True Cost of an Order Picking Error\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-9915326 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"9915326\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">A wrong item in a parcel, an incorrect quantity, a missing SKU: in most warehouses, order picking errors are treated as an unavoidable hazard, absorbed into operating costs. This is precisely what makes them expensive as long as they go unmeasured, they never trigger an optimisation decision.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">This article provides a comprehensive framework for assessing the true cost of a picking error, examining both visible and hidden costs while offering a rigorous method for quantifying the total impact across logistics operations.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-10ea316 e-con-full e-flex e-con e-child\" data-id=\"10ea316\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-fefd35c elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"fefd35c\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">The picking error: a routine event, cascading consequences<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-c67949f elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"c67949f\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Order picking concentrates the bulk of error risk within a warehouse. Still largely manual, repetitive and performed under throughput pressure, it combines every factor conducive to human error.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">It is also the most economically significant operation. Landmark academic research by Ren\u00e9 de Koster, Tho Le-Duc and Kees Jan Roodbergen, published in 2007 in one of the most prestigious operations research journals, the <\/span><i><span style=\"font-weight: 400;\">European Journal of Operational Research<\/span><\/i><span style=\"font-weight: 400;\">, demonstrates that order picking accounts for up to 55 % of total warehouse operating costs.<\/span><span style=\"font-weight: 400;\">1<\/span><span style=\"font-weight: 400;\"> Any quality deviation at this stage therefore weighs mechanically more than anywhere else in the supply chain.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">To better classify these failures, the table below details the four main families of picking errors observed in the field :<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-bddd74f e-con-full e-flex e-con e-child\" data-id=\"bddd74f\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-af9ba61 elementor-widget elementor-widget-html\" data-id=\"af9ba61\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"html.default\">\n\t\t\t\t\t<div>\n<meta charset=\"UTF-8\">\n<meta name=\"viewport\" content=\"width=device-width, initial-scale=1.0\">\n<style>\n  .balea-gamme-wrapper {\n    font-family: Roboto, Helvetica, sans-serif;\n    font-size: 14px;\n    color: #2a809c;\n    width: 100%;\n  }\n  .balea-gamme-wrapper h2 {\n    font-weight: 700;\n    font-size: 16px;\n    margin: 0 0 50px 0;\n    color: #1a2636;\n  }\n  \/* Mobile hint *\/\n  .balea-scroll-hint {\n    display: none;\n    background: #f0f4f8;\n    border-left: 3px solid #e8860a;\n    padding: 8px 12px;\n    margin-bottom: 10px;\n    font-size: 13px;\n    color: #1a2636;\n  }\n  .balea-scroll-hint span {\n    display: inline-block;\n    animation: swipe 1.4s ease-in-out infinite;\n  }\n  @keyframes swipe {\n    0%, 100% { transform: translateX(0); }\n    50% { transform: translateX(6px); }\n  }\n  \/* Table scroll container *\/\n  .balea-table-scroll {\n    width: 100%;\n    overflow-x: auto;\n    -webkit-overflow-scrolling: touch;\n  }\n  table.balea-table {\n    border-collapse: collapse;\n    width: 100%;\n    min-width: 720px;\n    \n  }\n  \/* HEADER *\/\n  table.balea-table thead tr th {\n    background-color: #4f5e75;\n    color: #ffffff;\n    font-weight: 600;\n    font-size: 13px;\n    padding: 11px 12px;\n    text-align: left;\n    vertical-align: middle;\n    line-height: 1.35;\n  }\n  \/* Last column header: orange *\/\n  table.balea-table thead tr th:last-child {\n    background-color: #2a809c;\n    color: #ffffff;\n    border-color: #2a809c;\n  }\n  \/* BODY ROWS *\/\n  table.balea-table tbody tr td {\n    padding: 10px 12px;\n    border: 1px solid #d0d7df;\n    vertical-align: middle;\n    color: #1a2636;\n    line-height: 1.4;\n  }\n  \/* Alternating rows *\/\n  table.balea-table tbody tr:nth-child(odd) td {\n    background-color: #ffffff;\n  }\n  table.balea-table tbody tr:nth-child(even) td {\n    background-color: #f4f6f9;\n  }\n  \/* Mod\u00e8le column: bold + navy *\/\n  table.balea-table tbody tr td:first-child {\n    font-weight: 700;\n    color: #2b3a4e;\n  }\n  \/* Hover row *\/\n  table.balea-table tbody tr:hover td {\n    background-color: #eaf0f7;\n  }\n  \/* MOBILE *\/\n  @media (max-width: 768px) {\n    .balea-scroll-hint {\n      display: block;\n    }\n    table.balea-table {\n      min-width: 680px;\n    }\n    table.balea-table thead tr th,\n    table.balea-table tbody tr td {\n      font-size: 12px;\n      padding: 9px 10px;\n    }\n  }\n<\/style>\n<div class=\"balea-gamme-wrapper\">\n  <div class=\"balea-scroll-hint\">\n    <span>\ud83d\udc49<\/span>&nbsp; Swipe to see all columns\n  <\/div>\n  <div class=\"balea-table-scroll\">\n    <table class=\"balea-table\">\n      <thead>\n        <tr>\n          <th style=\"border-radius :15px 0 0 0; width:200px;\">Error family<\/th>\n<th style=\"text-align:center; width:200px;\">Description<\/th>\n<th style=\"text-align:center; width:200px;\">Common operational cause<\/th>\n<th style=\"text-align:center; width:200px; border-radius :0 15px 0 0;\">Direct impact<\/th>\n        <\/tr>\n      <\/thead>\n      <tbody>\n        <tr>\n          <td>SKU error<\/td>\n<td style=\"text-align:center;\">Picking the wrong product instead of the correct one.<\/td>\n<td style=\"text-align:center;\">Visual similarity or adjacent storage of close SKUs.<\/td>\n<td style=\"text-align:center;\">Non-conforming delivery, product return.<\/td> \n        <\/tr>\n        <tr>\n          <td>Quantity error<\/td>\n<td style=\"text-align:center;\">Incorrect item count, over-pick or short-pick.<\/td>\n<td style=\"text-align:center;\">Manual counting error under throughput pressure.<\/td>\n<td style=\"text-align:center;\">Stock loss (over-pick) or customer dissatisfaction (short-pick).<\/td> \n        <\/tr>\n        <tr>\n          <td>Omission<\/td>\n<td style=\"text-align:center;\">An order line left unprocessed and missing from the final parcel.<\/td>\n<td style=\"text-align:center;\">Visual line skip on a paper pick list or premature validation.<\/td>\n<td style=\"text-align:center;\">Incomplete order, backorder to ship.<\/td> \n        <\/tr>\n        <tr>\n          <td>Allocation error<\/td>\n<td style=\"text-align:center;\">Correct product placed in the wrong container.<\/td>\n<td style=\"text-align:center;\">No poka-yoke or guidance during multi-order picking sessions.<\/td>\n<td style=\"text-align:center;\">Parcel inversion between two distinct customers.<\/td>\n        <\/tr>\n    <\/table>\n  <\/div>\n<\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ba087ed elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"ba087ed\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Scientific studies conducted by the Technical University of Munich (TUM) confirm that the average error rate in manual picking is approximately 0.3 % of lines picked.<\/span><span style=\"font-weight: 400;\">2<\/span><span style=\"font-weight: 400;\"> Although this percentage appears marginal at first glance, it becomes critical when scaled to volume: a warehouse shipping 2,000 orders per day produces, at this rate, 6 errors daily roughly 1,500 incidents per year.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-3314841 e-con-full e-flex e-con e-child\" data-id=\"3314841\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-254fd1d elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"254fd1d\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">The direct cost : the tip of the iceberg\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-f0cf0e1 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"f0cf0e1\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">The most visible and best-documented cost by supply chain managers is the direct logistics cost.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">The landmark global study conducted by Intermec across 250 logistics managers in Europe (France, Germany, the UK) and the United States estimates the direct unit cost of a single picking incident at approximately $22.<\/span><span style=\"font-weight: 400;\">3<\/span><span style=\"font-weight: 400;\"> The same study puts average annual losses incurred by a distribution centre due to picking errors and data-entry failures at close to $390,000.<\/span><span style=\"font-weight: 400;\">3<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">The Intermec survey reveals a concerning reality: approximately 35 % of logistics sites experience a consistently high error rate of 1 % or above, while 19 % of companies do not even measure the frequency of their picking errors effectively navigating blind.<\/span><span style=\"font-weight: 400;\">3<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">This average direct unit cost is explained by a chain of unproductive logistics tasks :<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ed3a9c7 elementor-icon-list--layout-traditional elementor-list-item-link-full_width elementor-invisible elementor-widget elementor-widget-icon-list\" data-id=\"ed3a9c7\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"icon-list.default\">\n\t\t\t\t\t\t\t<ul class=\"elementor-icon-list-items\">\n\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-check-circle\" viewBox=\"0 0 512 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M504 256c0 136.967-111.033 248-248 248S8 392.967 8 256 119.033 8 256 8s248 111.033 248 248zM227.314 387.314l184-184c6.248-6.248 6.248-16.379 0-22.627l-22.627-22.627c-6.248-6.249-16.379-6.249-22.628 0L216 308.118l-70.059-70.059c-6.248-6.248-16.379-6.248-22.628 0l-22.627 22.627c-6.248 6.248-6.248 16.379 0 22.627l104 104c6.249 6.249 16.379 6.249 22.628.001z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Double transport (initial shipment of the incorrect product, then the return flow).<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-check-circle\" viewBox=\"0 0 512 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M504 256c0 136.967-111.033 248-248 248S8 392.967 8 256 119.033 8 256 8s248 111.033 248 248zM227.314 387.314l184-184c6.248-6.248 6.248-16.379 0-22.627l-22.627-22.627c-6.248-6.249-16.379-6.249-22.628 0L216 308.118l-70.059-70.059c-6.248-6.248-16.379-6.248-22.628 0l-22.627 22.627c-6.248 6.248-6.248 16.379 0 22.627l104 104c6.249 6.249 16.379 6.249 22.628.001z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Return-receipt processing (quality inspection of the returned item, IT and physical stock reintegration, or disposal).<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-check-circle\" viewBox=\"0 0 512 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M504 256c0 136.967-111.033 248-248 248S8 392.967 8 256 119.033 8 256 8s248 111.033 248 248zM227.314 387.314l184-184c6.248-6.248 6.248-16.379 0-22.627l-22.627-22.627c-6.248-6.249-16.379-6.249-22.628 0L216 308.118l-70.059-70.059c-6.248-6.248-16.379-6.248-22.628 0l-22.627 22.627c-6.248 6.248-6.248 16.379 0 22.627l104 104c6.249 6.249 16.379 6.249 22.628.001z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Full re-execution of the order (new pick, packing, labelling) and rush re-shipment.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-check-circle\" viewBox=\"0 0 512 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M504 256c0 136.967-111.033 248-248 248S8 392.967 8 256 119.033 8 256 8s248 111.033 248 248zM227.314 387.314l184-184c6.248-6.248 6.248-16.379 0-22.627l-22.627-22.627c-6.248-6.249-16.379-6.249-22.628 0L216 308.118l-70.059-70.059c-6.248-6.248-16.379-6.248-22.628 0l-22.627 22.627c-6.248 6.248-6.248 16.379 0 22.627l104 104c6.249 6.249 16.379 6.249 22.628.001z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Financial immobilisation of the product throughout the entire reverse logistics cycle.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-f853bfd elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"f853bfd\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">However, this amount covers only the purely logistics mechanism. In sectors with stringent requirements, $22 often represents no more than the first line of a far heavier financial loss.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-c4acb9b e-con-full e-flex e-con e-child\" data-id=\"c4acb9b\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-705b18c elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"705b18c\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Hidden costs : where the bill escalates\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1a5d495 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"1a5d495\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Non-quality analysis reveals that indirect costs far exceed direct transport and handling expenses. The table below details the nature of these hidden costs and their medium-term consequences for the business :<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-285d4d7 elementor-widget elementor-widget-html\" data-id=\"285d4d7\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"html.default\">\n\t\t\t\t\t<div>\n<meta charset=\"UTF-8\">\n<meta name=\"viewport\" content=\"width=device-width, initial-scale=1.0\">\n<style>\n  .balea-gamme-wrapper {\n    font-family: Roboto, Helvetica, sans-serif;\n    font-size: 14px;\n    color: #2a809c;\n    width: 100%;\n  }\n  .balea-gamme-wrapper h2 {\n    font-weight: 700;\n    font-size: 16px;\n    margin: 0 0 50px 0;\n    color: #1a2636;\n  }\n  \/* Mobile hint *\/\n  .balea-scroll-hint {\n    display: none;\n    background: #f0f4f8;\n    border-left: 3px solid #e8860a;\n    padding: 8px 12px;\n    margin-bottom: 10px;\n    font-size: 13px;\n    color: #1a2636;\n  }\n  .balea-scroll-hint span {\n    display: inline-block;\n    animation: swipe 1.4s ease-in-out infinite;\n  }\n  @keyframes swipe {\n    0%, 100% { transform: translateX(0); }\n    50% { transform: translateX(6px); }\n  }\n  \/* Table scroll container *\/\n  .balea-table-scroll {\n    width: 100%;\n    overflow-x: auto;\n    -webkit-overflow-scrolling: touch;\n  }\n  table.balea-table {\n    border-collapse: collapse;\n    width: 100%;\n    min-width: 720px;\n    \n  }\n  \/* HEADER *\/\n  table.balea-table thead tr th {\n    background-color: #4f5e75;\n    color: #ffffff;\n    font-weight: 600;\n    font-size: 13px;\n    padding: 11px 12px;\n    text-align: left;\n    vertical-align: middle;\n    line-height: 1.35;\n  }\n  \/* Last column header: orange *\/\n  table.balea-table thead tr th:last-child {\n    background-color: #2a809c;\n    color: #ffffff;\n    border-color: #2a809c;\n  }\n  \/* BODY ROWS *\/\n  table.balea-table tbody tr td {\n    padding: 10px 12px;\n    border: 1px solid #d0d7df;\n    vertical-align: middle;\n    color: #1a2636;\n    line-height: 1.4;\n  }\n  \/* Alternating rows *\/\n  table.balea-table tbody tr:nth-child(odd) td {\n    background-color: #ffffff;\n  }\n  table.balea-table tbody tr:nth-child(even) td {\n    background-color: #f4f6f9;\n  }\n  \/* Mod\u00e8le column: bold + navy *\/\n  table.balea-table tbody tr td:first-child {\n    font-weight: 700;\n    color: #2b3a4e;\n  }\n  \/* Hover row *\/\n  table.balea-table tbody tr:hover td {\n    background-color: #eaf0f7;\n  }\n  \/* MOBILE *\/\n  @media (max-width: 768px) {\n    .balea-scroll-hint {\n      display: block;\n    }\n    table.balea-table {\n      min-width: 680px;\n    }\n    table.balea-table thead tr th,\n    table.balea-table tbody tr td {\n      font-size: 12px;\n      padding: 9px 10px;\n    }\n  }\n<\/style>\n<div class=\"balea-gamme-wrapper\">\n  <div class=\"balea-scroll-hint\">\n    <span>\ud83d\udc49<\/span>&nbsp; Swipe to see all columns\n  <\/div>\n  <div class=\"balea-table-scroll\">\n    <table class=\"balea-table\">\n      <thead>\n        <tr>\n          <th style=\"border-radius :15px 0 0 0; width:300px;\">Hidden cost<\/th>\n<th style=\"text-align:center; width:300px;\">Trigger mechanism<\/th>\n<th style=\"text-align:center; width:300px; border-radius :0 15px 0 0;\">Financial consequence<\/th>\n        <\/tr>\n      <\/thead>\n      <tbody>\n        <tr>\n          <td>After-sales dispute cost<\/td>\n<td style=\"text-align:center;\">Administrative handling of the customer complaint by the sales team.<\/td>\n<td style=\"text-align:center;\">FTE mobilisation in support, credit notes issued and commercial gestures granted.<\/td>\n        <\/tr>\n        <tr>\n          <td>Contractual cost<\/td>\n<td style=\"text-align:center;\">Failure to meet service-level agreements (SLAs) with a 3PL client.<\/td>\n<td style=\"text-align:center;\">Contractual penalties applied and significant risk of contract non-renewal.<\/td>\n        <\/tr>\n        <tr>\n          <td>Regulatory cost<\/td>\n<td style=\"text-align:center;\">Traceability errors, incorrect batch numbers or expiry dates in pharmaceutical or food logistics.<\/td>\n<td style=\"text-align:center;\">Non-conformance audit procedures, product recall campaigns and major legal exposure.<\/td>\n        <\/tr>\n        <tr>\n          <td>Commercial cost<\/td>\n<td style=\"text-align:center;\">Brand image degradation and deterioration of the end-customer buying experience.<\/td>\n<td style=\"text-align:center;\">Permanent customer loss (churn) and increased marketing acquisition costs to compensate.<\/td>\n        <\/tr>\n        <tr>\n          <td>Structural cost<\/td>\n<td style=\"text-align:center;\">Addition of systematic manual checkpoint stations at the end of line to intercept errors.<\/td>\n<td style=\"text-align:center;\">Non-quality transformed into a recurring fixed cost, penalising overall productivity.<\/td>\n        <\/tr>\n    <\/table>\n  <\/div>\n<\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-b9405b8 e-con-full e-flex e-con e-child\" data-id=\"b9405b8\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-c311139 elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"c311139\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">The method : quantifying order picking error costs in the warehouse\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3c746f0 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"3c746f0\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">To build a coherent budget case for quality-improvement technologies, the true cost of errors should be calculated using a precise formula :<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-293978a elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"293978a\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: center;\"><b>C<\/b><b>total<\/b><b> = V<\/b><b>annual<\/b><b> \u00d7 E<\/b><b>rate<\/b><b> \u00d7 C<\/b><b>unit<\/b><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-04cc0fb elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"04cc0fb\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\">Where :<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1a9b073 elementor-icon-list--layout-traditional elementor-list-item-link-full_width elementor-invisible elementor-widget elementor-widget-icon-list\" data-id=\"1a9b073\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"icon-list.default\">\n\t\t\t\t\t\t\t<ul class=\"elementor-icon-list-items\">\n\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-check-circle\" viewBox=\"0 0 512 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M504 256c0 136.967-111.033 248-248 248S8 392.967 8 256 119.033 8 256 8s248 111.033 248 248zM227.314 387.314l184-184c6.248-6.248 6.248-16.379 0-22.627l-22.627-22.627c-6.248-6.249-16.379-6.249-22.628 0L216 308.118l-70.059-70.059c-6.248-6.248-16.379-6.248-22.628 0l-22.627 22.627c-6.248 6.248-6.248 16.379 0 22.627l104 104c6.249 6.249 16.379 6.249 22.628.001z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Vannual is the annual volume of orders processed by the site.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-check-circle\" viewBox=\"0 0 512 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M504 256c0 136.967-111.033 248-248 248S8 392.967 8 256 119.033 8 256 8s248 111.033 248 248zM227.314 387.314l184-184c6.248-6.248 6.248-16.379 0-22.627l-22.627-22.627c-6.248-6.249-16.379-6.249-22.628 0L216 308.118l-70.059-70.059c-6.248-6.248-16.379-6.248-22.628 0l-22.627 22.627c-6.248 6.248-6.248 16.379 0 22.627l104 104c6.249 6.249 16.379 6.249 22.628.001z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Erate is the actual picking error rate, measured through rigorous sampling \u2014 not solely from customer complaints.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-check-circle\" viewBox=\"0 0 512 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M504 256c0 136.967-111.033 248-248 248S8 392.967 8 256 119.033 8 256 8s248 111.033 248 248zM227.314 387.314l184-184c6.248-6.248 6.248-16.379 0-22.627l-22.627-22.627c-6.248-6.249-16.379-6.249-22.628 0L216 308.118l-70.059-70.059c-6.248-6.248-16.379-6.248-22.628 0l-22.627 22.627c-6.248 6.248-6.248 16.379 0 22.627l104 104c6.249 6.249 16.379 6.249 22.628.001z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Cunit is the full unit cost calculated per error type.<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-086fe97 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"086fe97\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">The table below details the three steps required to populate this formula with reliable, operationally representative data :<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-41d478e elementor-widget elementor-widget-html\" data-id=\"41d478e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"html.default\">\n\t\t\t\t\t<div>\n<meta charset=\"UTF-8\">\n<meta name=\"viewport\" content=\"width=device-width, initial-scale=1.0\">\n<style>\n  .balea-gamme-wrapper {\n    font-family: Roboto, Helvetica, sans-serif;\n    font-size: 14px;\n    color: #2a809c;\n    width: 100%;\n  }\n  .balea-gamme-wrapper h2 {\n    font-weight: 700;\n    font-size: 16px;\n    margin: 0 0 50px 0;\n    color: #1a2636;\n  }\n  \/* Mobile hint *\/\n  .balea-scroll-hint {\n    display: none;\n    background: #f0f4f8;\n    border-left: 3px solid #e8860a;\n    padding: 8px 12px;\n    margin-bottom: 10px;\n    font-size: 13px;\n    color: #1a2636;\n  }\n  .balea-scroll-hint span {\n    display: inline-block;\n    animation: swipe 1.4s ease-in-out infinite;\n  }\n  @keyframes swipe {\n    0%, 100% { transform: translateX(0); }\n    50% { transform: translateX(6px); }\n  }\n  \/* Table scroll container *\/\n  .balea-table-scroll {\n    width: 100%;\n    overflow-x: auto;\n    -webkit-overflow-scrolling: touch;\n  }\n  table.balea-table {\n    border-collapse: collapse;\n    width: 100%;\n    min-width: 720px;\n    \n  }\n  \/* HEADER *\/\n  table.balea-table thead tr th {\n    background-color: #4f5e75;\n    color: #ffffff;\n    font-weight: 600;\n    font-size: 13px;\n    padding: 11px 12px;\n    text-align: left;\n    vertical-align: middle;\n    line-height: 1.35;\n  }\n  \/* Last column header: orange *\/\n  table.balea-table thead tr th:last-child {\n    background-color: #2a809c;\n    color: #ffffff;\n    border-color: #2a809c;\n  }\n  \/* BODY ROWS *\/\n  table.balea-table tbody tr td {\n    padding: 10px 12px;\n    border: 1px solid #d0d7df;\n    vertical-align: middle;\n    color: #1a2636;\n    line-height: 1.4;\n  }\n  \/* Alternating rows *\/\n  table.balea-table tbody tr:nth-child(odd) td {\n    background-color: #ffffff;\n  }\n  table.balea-table tbody tr:nth-child(even) td {\n    background-color: #f4f6f9;\n  }\n  \/* Mod\u00e8le column: bold + navy *\/\n  table.balea-table tbody tr td:first-child {\n    font-weight: 700;\n    color: #2b3a4e;\n  }\n  \/* Hover row *\/\n  table.balea-table tbody tr:hover td {\n    background-color: #eaf0f7;\n  }\n  \/* MOBILE *\/\n  @media (max-width: 768px) {\n    .balea-scroll-hint {\n      display: block;\n    }\n    table.balea-table {\n      min-width: 680px;\n    }\n    table.balea-table thead tr th,\n    table.balea-table tbody tr td {\n      font-size: 12px;\n      padding: 9px 10px;\n    }\n  }\n<\/style>\n<div class=\"balea-gamme-wrapper\">\n  <div class=\"balea-scroll-hint\">\n    <span>\ud83d\udc49<\/span>&nbsp; Swipe to see all columns\n  <\/div>\n  <div class=\"balea-table-scroll\">\n    <table class=\"balea-table\">\n      <thead>\n        <tr>\n          <th style=\"border-radius :15px 0 0 0; width:300px;\">Calculation step<\/th>\n<th style=\"text-align:center; width:300px;\">Operational objective<\/th>\n<th style=\"text-align:center; width:300px; border-radius :0 15px 0 0;\">Practical method<\/th>\n        <\/tr>\n      <\/thead>\n      <tbody>\n        <tr>\n          <td>1. Establish the true error rate<\/td>\n<td style=\"text-align:center;\">Move beyond the bias of unreported customer complaints (e.g. over-shipped items that go unmentioned).<\/td>\n<td style=\"text-align:center;\">Implement statistical sampling over a defined period to obtain an objective baseline.<\/td>\n        <\/tr>\n        <tr>\n          <td>2. Value the full cost<\/td>\n<td style=\"text-align:center;\">Capture all expenses generated by the error beyond transport alone.<\/td>\n<td style=\"text-align:center;\">Model per error type: the sum of transport, after-sales labour, reprocessing and penalties.<\/td>\n        <\/tr>\n        <tr>\n          <td>3. Reintegrate structural costs<\/td>\n<td style=\"text-align:center;\">Make visible the correction costs buried in other cost centres.<\/td>\n<td style=\"text-align:center;\">Calculate the operating cost of double-check stations and corrective packaging activities.<\/td>\n        <\/tr>\n    <\/table>\n  <\/div>\n<\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-f2e0cbf elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"f2e0cbf\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">As an illustration, if the 1,500 annual errors of a typical warehouse are valued at the direct cost alone of $22, the direct loss already stands at $33,000 per year. The massive gap between this baseline and the $390,000 average annual losses measured by Intermec demonstrates the preponderance of hidden costs.<\/span><span style=\"font-weight: 400;\">3<\/span><span style=\"font-weight: 400;\"> The true full cost of an error turns out to be a multiple of its apparent logistics cost.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Once this calculation is shared, the issue changes scale: the picking error stops being an operational inevitability and emerges as a reservoir of savings and rapid return on investment (ROI).<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<img decoding=\"async\" class=\"e-image-base e-c9dfb83-ca6eb26\" data-interaction-id=\"c9dfb83\" data-e-type=\"widget\" data-id=\"c9dfb83\" id=\"9079\" src=\"https:\/\/www.balea.com\/wp-content\/uploads\/2026\/08\/encart-2-v02.jpg\" width=\"1374\" height=\"1121\" srcset=\"https:\/\/www.balea.com\/wp-content\/uploads\/2026\/08\/encart-2-v02.jpg 1374w, https:\/\/www.balea.com\/wp-content\/uploads\/2026\/08\/encart-2-v02-1080x881.jpg 1080w, https:\/\/www.balea.com\/wp-content\/uploads\/2026\/08\/encart-2-v02-1324x1080.jpg 1324w\" alt=\"\"\/>\t\t<div class=\"elementor-element elementor-element-aa923c3 e-con-full e-flex e-con e-child\" data-id=\"aa923c3\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-7e4ce71 elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"7e4ce71\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Reducing the error rate without slowing throughput\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8f0a4f4 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"8f0a4f4\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p dir=\"ltr\">The traditional reflex is to add human control after picking, through a visual double-check at the end of the line. While effective at catching certain errors, this method locks in high structural costs and significantly slows down overall shipping throughput.<\/p><p dir=\"ltr\">Modern design approaches reverse this paradigm by embedding control directly at the heart of the picking action.<\/p><p dir=\"ltr\">The Intermec study further points out that a picking operator loses an average of 15 minutes of productivity per day due to inefficient processes or lost connections on their handheld terminals.\u00b3 Yet more than 60% of supply chain managers agree that saving just a few seconds in task-execution processes generates substantial savings in both time and money.\u00b3<\/p><p dir=\"ltr\">To meet these demands for speed and precision without compromise, several technology solutions are available to support the operator on a daily basis:<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4d62e43 elementor-widget elementor-widget-html\" data-id=\"4d62e43\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"html.default\">\n\t\t\t\t\t<div>\n<meta charset=\"UTF-8\">\n<meta name=\"viewport\" content=\"width=device-width, initial-scale=1.0\">\n<style>\n  .balea-gamme-wrapper {\n    font-family: Roboto, Helvetica, sans-serif;\n    font-size: 14px;\n    color: #2a809c;\n    width: 100%;\n  }\n  .balea-gamme-wrapper h2 {\n    font-weight: 700;\n    font-size: 16px;\n    margin: 0 0 50px 0;\n    color: #1a2636;\n  }\n  \/* Mobile hint *\/\n  .balea-scroll-hint {\n    display: none;\n    background: #f0f4f8;\n    border-left: 3px solid #e8860a;\n    padding: 8px 12px;\n    margin-bottom: 10px;\n    font-size: 13px;\n    color: #1a2636;\n  }\n  .balea-scroll-hint span {\n    display: inline-block;\n    animation: swipe 1.4s ease-in-out infinite;\n  }\n  @keyframes swipe {\n    0%, 100% { transform: translateX(0); }\n    50% { transform: translateX(6px); }\n  }\n  \/* Table scroll container *\/\n  .balea-table-scroll {\n    width: 100%;\n    overflow-x: auto;\n    -webkit-overflow-scrolling: touch;\n  }\n  table.balea-table {\n    border-collapse: collapse;\n    width: 100%;\n    min-width: 720px;\n    \n  }\n  \/* HEADER *\/\n  table.balea-table thead tr th {\n    background-color: #4f5e75;\n    color: #ffffff;\n    font-weight: 600;\n    font-size: 13px;\n    padding: 11px 12px;\n    text-align: left;\n    vertical-align: middle;\n    line-height: 1.35;\n  }\n  \/* Last column header: orange *\/\n  table.balea-table thead tr th:last-child {\n    background-color: #2a809c;\n    color: #ffffff;\n    border-color: #2a809c;\n  }\n  \/* BODY ROWS *\/\n  table.balea-table tbody tr td {\n    padding: 10px 12px;\n    border: 1px solid #d0d7df;\n    vertical-align: middle;\n    color: #1a2636;\n    line-height: 1.4;\n  }\n  \/* Alternating rows *\/\n  table.balea-table tbody tr:nth-child(odd) td {\n    background-color: #ffffff;\n  }\n  table.balea-table tbody tr:nth-child(even) td {\n    background-color: #f4f6f9;\n  }\n  \/* Mod\u00e8le column: bold + navy *\/\n  table.balea-table tbody tr td:first-child {\n    font-weight: 700;\n    color: #2b3a4e;\n  }\n  \/* Hover row *\/\n  table.balea-table tbody tr:hover td {\n    background-color: #eaf0f7;\n  }\n  \/* MOBILE *\/\n  @media (max-width: 768px) {\n    .balea-scroll-hint {\n      display: block;\n    }\n    table.balea-table {\n      min-width: 680px;\n    }\n    table.balea-table thead tr th,\n    table.balea-table tbody tr td {\n      font-size: 12px;\n      padding: 9px 10px;\n    }\n  }\n<\/style>\n<div class=\"balea-gamme-wrapper\">\n  <div class=\"balea-scroll-hint\">\n    <span>\ud83d\udc49<\/span>&nbsp; Swipe to see all columns\n  <\/div>\n  <div class=\"balea-table-scroll\">\n    <table class=\"balea-table\">\n      <thead>\n        <tr>\n          <th style=\"border-radius :15px 0 0 0; width:200px;\">Technology solution<\/th>\n<th style=\"text-align:center; width:350px;\">Control mode and mechanism<\/th>\n<th style=\"text-align:center; width:350px; border-radius :0 15px 0 0;\">Main operational advantage<\/th>\n        <\/tr>\n      <\/thead>\n      <tbody>\n        <tr>\n          <td>Operator light guidance<\/td>\n<td style=\"text-align:center;\">Put-to-Light system or direct light indicator on the target container on the trolley.<\/td>\n<td style=\"text-align:center;\">Eliminates hesitation during item deposit in multi-order workflows.<\/td>\n        <\/tr>\n        <tr>\n          <td>Real-time weight-based validation<\/td>\n<td style=\"text-align:center;\">Precision on-board weighing integrated into trolley trays or fixed stations.<\/td>\n<td style=\"text-align:center;\">Instant detection of any weight discrepancy (wrong SKU or quantity) at the moment of deposit.<\/td>\n        <\/tr>\n        <tr>\n          <td>Photographic traceability<\/td>\n<td style=\"text-align:center;\">Automated photo capture of the container at each picking step (Instapick system).<\/td>\n<td style=\"text-align:center;\">Indisputable proof of conformity against customer claims (\u201cclaim killer\u201d).<\/td>\n        <\/tr>\n        <tr>\n          <td>Machine-learning weight intelligence<\/td>\n<td style=\"text-align:center;\">Dynamic, automatic calculation of SKU weights through learning from picking data.<\/td>\n<td style=\"text-align:center;\">Simplifies maintenance of item weight master data.<\/td>\n        <\/tr>\n    <\/table>\n  <\/div>\n<\/div>\n<\/div>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-0d550b2 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"0d550b2\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">By leveraging the smart picking solutions developed by Balea, companies gain access to breakthrough technologies.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Integrating weight-based validation on intelligent picking trolleys such as the Balea Shopeur, capable of processing up to 48 simultaneous orders, combines high-precision weight verification with systematic scanning<\/span><span style=\"font-family: -apple-system, BlinkMacSystemFont, 'Segoe UI', Roboto, 'Helvetica Neue', Arial, 'Noto Sans', sans-serif, 'Apple Color Emoji', 'Segoe UI Emoji', 'Segoe UI Symbol', 'Noto Color Emoji';\">.<\/span><sub style=\"font-family: -apple-system, BlinkMacSystemFont, 'Segoe UI', Roboto, 'Helvetica Neue', Arial, 'Noto Sans', sans-serif, 'Apple Color Emoji', 'Segoe UI Emoji', 'Segoe UI Symbol', 'Noto Color Emoji';\">4<\/sub><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Verification takes place transparently for the operator at the moment of pick, with no additional administrative task.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Similarly, deploying a fixed order-weighing station or adopting an on-board weighing system on material-handling equipment makes it possible to secure 100 % of flows.<\/span><span style=\"font-weight: 400;\">5<\/span><span style=\"font-weight: 400;\"> With orchestration by the Solea WES software suite, the warehouse combines a 100 % conformity rate with maximum productivity<\/span><span style=\"text-align: justify; font-family: -apple-system, BlinkMacSystemFont, 'Segoe UI', Roboto, 'Helvetica Neue', Arial, 'Noto Sans', sans-serif, 'Apple Color Emoji', 'Segoe UI Emoji', 'Segoe UI Symbol', 'Noto Color Emoji';\">.<\/span><sub style=\"text-align: justify; font-family: -apple-system, BlinkMacSystemFont, 'Segoe UI', Roboto, 'Helvetica Neue', Arial, 'Noto Sans', sans-serif, 'Apple Color Emoji', 'Segoe UI Emoji', 'Segoe UI Symbol', 'Noto Color Emoji';\">4<\/sub><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<img decoding=\"async\" class=\"e-image-base e-09db73d-4460818\" data-interaction-id=\"09db73d\" data-e-type=\"widget\" data-id=\"09db73d\" id=\"9079\" src=\"https:\/\/www.balea.com\/wp-content\/uploads\/2026\/08\/encart-2-v02-1080x881.jpg\" width=\"1080\" height=\"881\" srcset=\"https:\/\/www.balea.com\/wp-content\/uploads\/2026\/08\/encart-2-v02-1080x881.jpg 1080w, https:\/\/www.balea.com\/wp-content\/uploads\/2026\/08\/encart-2-v02-1324x1080.jpg 1324w, https:\/\/www.balea.com\/wp-content\/uploads\/2026\/08\/encart-2-v02.jpg 1374w\" alt=\"\"\/>\t\t<div class=\"elementor-element elementor-element-7af5492 e-con-full e-flex e-con e-child\" data-id=\"7af5492\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-3fa2c8e elementor-invisible elementor-widget elementor-widget-heading\" data-id=\"3fa2c8e\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Order picking errors : a measurable cost, therefore a manageable one\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-0af4d37 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"0af4d37\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Order picking errors are neither an operational inevitability nor a secondary quality indicator: they represent a major recurring expense whose annual cost often equals the investment required to eliminate them.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">The first step is to precisely quantify this non-quality within the site; the second is to identify the logistics process stages that generate it.<\/span><\/p><p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">Balea&#8217;s expert teams work alongside supply chain professionals on the ground every day to carry out these analyses, design tailored solutions and deliver a rapid return on investment, typically under 18 months.<\/span><span style=\"font-weight: 400;\">6<\/span><\/p><p style=\"text-align: justify;\"><b>To start this optimisation process, reach out to the technical team for a personalised warehouse logistics audit.<\/b><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8a20ba9 elementor-invisible elementor-widget elementor-widget-text-editor\" data-id=\"8a20ba9\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeInUp&quot;}\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\"><em><strong>Sources<\/strong><\/em><\/p><ol><li><em><span style=\"font-weight: 400;\"> De Koster, R., Le-Duc, T. &amp; Roodbergen, K.J. (2007). &#8220;Design and control of warehouse order picking: A literature review.&#8221; European Journal of Operational Research, 182(2), 481\u2013501.<\/span><\/em><\/li><li><em><span style=\"font-weight: 400;\"> Rammelmeier, T., Galka, S. &amp; G\u00fcnthner, W.A. (2012). &#8220;Fehlervermeidung in der Kommissionierung.&#8221; Lehrstuhl f\u00fcr F\u00f6rdertechnik Materialfluss Logistik (fml), Technische Universit\u00e4t M\u00fcnchen.<\/span><\/em><\/li><li><em><span style=\"font-weight: 400;\"> Intermec \/ Vanson Bourne (2012). &#8220;The true cost of errors in order fulfillment.&#8221; International study across 250 logistics managers in Europe and the United States.<\/span><\/em><\/li><li><em><span style=\"font-weight: 400;\"> Balea \u2014 Smart picking solutions. https:\/\/www.balea.com\/<\/span><\/em><\/li><li><em><span style=\"font-weight: 400;\"> Balea \u2014 Solea WES software suite. https:\/\/www.balea.com\/solea\/<\/span><\/em><\/li><li><em><span style=\"font-weight: 400;\"> Balea \u2014 Unit-level order picking. https:\/\/www.balea.com\/<\/span><\/em><\/li><\/ol>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-0834faf e-con-full e-flex e-con e-child\" data-id=\"0834faf\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;sticky&quot;:&quot;top&quot;,&quot;sticky_offset&quot;:100,&quot;sticky_parent&quot;:&quot;yes&quot;,&quot;sticky_on&quot;:[&quot;desktop&quot;,&quot;laptop&quot;,&quot;tablet_extra&quot;,&quot;tablet&quot;,&quot;mobile_extra&quot;,&quot;mobile&quot;],&quot;sticky_effects_offset&quot;:0,&quot;sticky_anchor_link_offset&quot;:0}\">\n\t\t<div class=\"elementor-element elementor-element-a1ea934 e-con-full e-flex elementor-invisible e-con e-child\" data-id=\"a1ea934\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;,&quot;animation&quot;:&quot;fadeInUp&quot;,&quot;animation_delay&quot;:1200}\">\n\t\t\t\t<div class=\"elementor-element elementor-element-1ab5dd5 elementor-widget elementor-widget-heading\" data-id=\"1ab5dd5\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Topics<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-daa2fec elementor-icon-list--layout-traditional elementor-list-item-link-full_width elementor-widget elementor-widget-icon-list\" data-id=\"daa2fec\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"icon-list.default\">\n\t\t\t\t\t\t\t<ul class=\"elementor-icon-list-items\">\n\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-tags\" viewBox=\"0 0 640 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M497.941 225.941L286.059 14.059A48 48 0 0 0 252.118 0H48C21.49 0 0 21.49 0 48v204.118a48 48 0 0 0 14.059 33.941l211.882 211.882c18.744 18.745 49.136 18.746 67.882 0l204.118-204.118c18.745-18.745 18.745-49.137 0-67.882zM112 160c-26.51 0-48-21.49-48-48s21.49-48 48-48 48 21.49 48 48-21.49 48-48 48zm513.941 133.823L421.823 497.941c-18.745 18.745-49.137 18.745-67.882 0l-.36-.36L527.64 323.522c16.999-16.999 26.36-39.6 26.36-63.64s-9.362-46.641-26.36-63.64L331.397 0h48.721a48 48 0 0 1 33.941 14.059l211.882 211.882c18.745 18.745 18.745 49.137 0 67.882z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Order picking<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-tags\" viewBox=\"0 0 640 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M497.941 225.941L286.059 14.059A48 48 0 0 0 252.118 0H48C21.49 0 0 21.49 0 48v204.118a48 48 0 0 0 14.059 33.941l211.882 211.882c18.744 18.745 49.136 18.746 67.882 0l204.118-204.118c18.745-18.745 18.745-49.137 0-67.882zM112 160c-26.51 0-48-21.49-48-48s21.49-48 48-48 48 21.49 48 48-21.49 48-48 48zm513.941 133.823L421.823 497.941c-18.745 18.745-49.137 18.745-67.882 0l-.36-.36L527.64 323.522c16.999-16.999 26.36-39.6 26.36-63.64s-9.362-46.641-26.36-63.64L331.397 0h48.721a48 48 0 0 1 33.941 14.059l211.882 211.882c18.745 18.745 18.745 49.137 0 67.882z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Cost of non-quality<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-tags\" viewBox=\"0 0 640 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M497.941 225.941L286.059 14.059A48 48 0 0 0 252.118 0H48C21.49 0 0 21.49 0 48v204.118a48 48 0 0 0 14.059 33.941l211.882 211.882c18.744 18.745 49.136 18.746 67.882 0l204.118-204.118c18.745-18.745 18.745-49.137 0-67.882zM112 160c-26.51 0-48-21.49-48-48s21.49-48 48-48 48 21.49 48 48-21.49 48-48 48zm513.941 133.823L421.823 497.941c-18.745 18.745-49.137 18.745-67.882 0l-.36-.36L527.64 323.522c16.999-16.999 26.36-39.6 26.36-63.64s-9.362-46.641-26.36-63.64L331.397 0h48.721a48 48 0 0 1 33.941 14.059l211.882 211.882c18.745 18.745 18.745 49.137 0 67.882z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Warehouse performance<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-tags\" viewBox=\"0 0 640 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M497.941 225.941L286.059 14.059A48 48 0 0 0 252.118 0H48C21.49 0 0 21.49 0 48v204.118a48 48 0 0 0 14.059 33.941l211.882 211.882c18.744 18.745 49.136 18.746 67.882 0l204.118-204.118c18.745-18.745 18.745-49.137 0-67.882zM112 160c-26.51 0-48-21.49-48-48s21.49-48 48-48 48 21.49 48 48-21.49 48-48 48zm513.941 133.823L421.823 497.941c-18.745 18.745-49.137 18.745-67.882 0l-.36-.36L527.64 323.522c16.999-16.999 26.36-39.6 26.36-63.64s-9.362-46.641-26.36-63.64L331.397 0h48.721a48 48 0 0 1 33.941 14.059l211.882 211.882c18.745 18.745 18.745 49.137 0 67.882z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Smart picking<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-tags\" viewBox=\"0 0 640 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M497.941 225.941L286.059 14.059A48 48 0 0 0 252.118 0H48C21.49 0 0 21.49 0 48v204.118a48 48 0 0 0 14.059 33.941l211.882 211.882c18.744 18.745 49.136 18.746 67.882 0l204.118-204.118c18.745-18.745 18.745-49.137 0-67.882zM112 160c-26.51 0-48-21.49-48-48s21.49-48 48-48 48 21.49 48 48-21.49 48-48 48zm513.941 133.823L421.823 497.941c-18.745 18.745-49.137 18.745-67.882 0l-.36-.36L527.64 323.522c16.999-16.999 26.36-39.6 26.36-63.64s-9.362-46.641-26.36-63.64L331.397 0h48.721a48 48 0 0 1 33.941 14.059l211.882 211.882c18.745 18.745 18.745 49.137 0 67.882z\"><\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text\">Logistics traceability<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-20253b8 elementor-widget elementor-widget-template\" data-id=\"20253b8\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"template.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-template\">\n\t\t\t\t\t<div data-elementor-type=\"container\" data-elementor-id=\"11792\" class=\"elementor elementor-11792 elementor-8281 elementor-8281\" data-elementor-post-type=\"elementor_library\">\n\t\t\t\t<div class=\"elementor-element elementor-element-7868e328 e-con-full e-flex elementor-invisible e-con e-child\" data-id=\"7868e328\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;,&quot;animation&quot;:&quot;fadeInUp&quot;}\">\n\t\t\t\t<div class=\"elementor-element elementor-element-53d060a8 elementor-widget elementor-widget-heading\" data-id=\"53d060a8\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h3 class=\"elementor-heading-title elementor-size-default\">Need to talk to an expert?<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7504a030 elementor-widget elementor-widget-text-editor\" data-id=\"7504a030\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify;\">Our logistics experts are here to assist you and will answer your questions as soon as possible.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-59649ae3 elementor-widget elementor-widget-button\" data-id=\"59649ae3\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"button.default\">\n\t\t\t\t\t\t\t\t\t\t<a class=\"elementor-button elementor-button-link elementor-size-sm\" href=\"https:\/\/www.balea.com\/en\/discuss-your-project\/\">\n\t\t\t\t\t\t<span class=\"elementor-button-content-wrapper\">\n\t\t\t\t\t\t<span class=\"elementor-button-icon\">\n\t\t\t\t<i aria-hidden=\"true\" class=\"jki jki-mail-line\"><\/i>\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<span class=\"elementor-button-text\">Talk to an expert<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>The True Cost of an Order Picking Error A wrong item in a parcel, an incorrect quantity, a missing SKU: in most warehouses, order picking errors are treated as an unavoidable hazard, absorbed into operating costs. This is precisely what makes them expensive as long as they go unmeasured, they never trigger an optimisation decision. [&hellip;]<\/p>\n","protected":false},"author":2,"featured_media":9077,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"categories":[56],"tags":[],"class_list":["post-9080","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>The True Cost of an Order Picking Error | Balea<\/title>\n<meta name=\"description\" content=\"Direct cost, hidden costs and a calculation method: discover the true cost of a picking error \u2014 and how smart picking turns warehouse non-quality into fast ROI.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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