Find the real cause before choosing the fix
Pick the complaint you hear on the floor. Each guide shows what to look for, how to measure it, which causes to compare, and what to try during the next seven days.
Not sure about a term? Open the plain-English glossaryPicking is too slow
Find out whether workers are losing time to walking, searching, handling, waiting, or solving problems before choosing a fix.
Open the guide 02Picking errors are too high
Sort mistakes by type and find the first point where the order, item, quantity, or location became wrong.
Open the guide 03We miss carrier cutoffs
Follow late orders from release through shipping to find the step where work first fell behind.
Open the guide 04Workers spend too much time walking
Measure repeated walking, backtracking, crossings, and extra trips before paying for travel automation.
Open the guide 05Aisles and work cells are congested
Find out whether blocked aisles come from short demand spikes, crossing routes, refill work, poor equipment fit, or too much unfinished work.
Open the guide 06New workers take too long to train
Find the tasks, decisions, and exceptions that keep a new worker from working correctly without help.
Open the guide 07Temporary labor performs poorly
Check whether instructions, work difficulty, warm-up time, supervision, or an unrealistic target is holding temporary workers back.
Open the guide 08Forward locations keep stocking out
Find out why pick shelves run empty even when reserve stock exists, then set a refill trigger workers can meet.
Open the guide 09Packing cannot keep up with picking
Measure what packers actually do and whether uneven work, missing items, rework, or the station layout is creating the queue.
Open the guide 10Inventory records do not match reality
Trace a stock difference back to the first wrong move, count, status, unit, location, or computer message.
Open the guide 11Peak volume overwhelms the process
Compare demand and realistic capacity hour by hour to find the first step that cannot keep up.
Open the guide 12We need capacity without moving buildings
Recover space and output by reducing walking, searching, queues, poor shelf use, and repeated handling before considering another building.
Open the guide