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5 Common Warehouse Mistakes You Should Avoid

Today’s warehousing can be complicated due to technological advancements, high consumer expectations, and competitive delivery times. The pressure to keep up with these demands strains overall operations, making it essential to ensure seamless warehouse logistics. Discussed below are five common warehouse mistakes you should avoid.

Ignoring preventive maintenance

Warehouses present multiple safety hazards like rack collapse that may occur when various operation aspects fall behind their preventive maintenance schedule. Being proactive about maintenance helps avoid sudden warehouse failures that may result in severe injuries, downtime, and reduced productivity. It also ensures that you don’t lose productive time to OSHA investigations and pay fines or suffer less labor capacity because of injured employees. Regular preventive maintenance for dock doors, forklifts, and other warehouse items helps you identify and fix minor issues before they escalate, reducing warehouse costs.

A detailed preventive maintenance checklist for storage and handling, dock and door operations, and motive power ensures safety, saves unexpected costs, and improves warehouse productivity. You can source quality repair and replacement parts from PartsBrite loading dock parts or other trusted dock leveler part vendors.

Poor inventory management

Poor inventory management causes you to accept orders on the assumption that you have sufficient stock or reject orders on the belief that you have enough supply to meet them. You may also receive new items while you have enough stock, tying up more money in excess inventory. These indicate that you haven’t kept proper inventory records or updated them as needed. You can invest in an inventory management solution or warehouse management software that has real-time inventory management features to curb inventory management issues.

Poor seasonal demand preparedness

While some items have equal demand all year round, others are popular at specific times of the year. Unexpected demand influxes can be damaging, especially if your warehouse isn’t ready to take on the orders. Staying current with demand fluctuations and market trends for the products you deal in helps you prepare for the management of changing product demand.

You can determine what you need for your seasonal inventory with demand forecasting strategies. Staying in touch with your distributors, manufacturers, transporters, retailers, and other industry sources can help ensure that each supply chain part has similar information regarding demand fluctuations to work together and respond accordingly.

Bad warehouse layout

Ineffective space usage is a common warehouse pain point that results in insufficient storage. With an optimum warehouse layout plan, you can maximize vertical and floor space usage while ensuring sufficient room for the employees to move around freely. You can also find ways to use equipment and automation to improve product accessibility, systematically categorize inventory, ensure safe inventory storage and reduce labor and associated costs.

Warehouse picking errors

Warehouse picking mistakes are a significant concern for businesses looking to improve profitability and productivity. They impact customer satisfaction, revenues, and profit margins. Using technologies and implementing best practices can help reduce picking errors. Start by leveraging the right technology, including collaborative mobile robots or pick-to-light and put-to-light.

Regularly review your storage strategies and ensure each item is correctly labeled for easy identification. Establish regular inventory checks to ensure products are stored in their appropriate locations, reducing picking errors.


Warehouse management mistakes affect operations and cost you time and money. Familiarizing yourself with these common warehouse mistakes reduces or eliminates their effects on your business, increasing productivity and profitability and ensuring customer satisfaction.

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Written by S Dionne

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