Reduction of picking errors by 47.2% in a construction wholesaler
A wholesaler near Warsaw lost 12,400 PLN a month on returns of incorrectly shipped goods. We introduced a barcode verification system and changed the logic of goods placement on shelves.
The Bud-Max wholesaler near Warsaw had a logistics problem that was eating their profits. Every second order returned for correction because the customer received something other than what they ordered. We fixed this mess in 14 weeks, putting facts on the table instead of theoretical lectures.
The challenge
In March 2024, Bud-Max recorded 89 incorrect shipments in a single month. Warehouse workers looked for goods by feel because stock in the computer didn't match reality by 14.3%. Complaints took office workers 23 hours a week, and angry contractors were leaving for the competition. Each error cost the company an average of 139 PLN – including return transport, repacking time, and wasted materials. We count every zloty, so it quickly became apparent that the company was losing 12,400 PLN a month due to pure procedural negligence.
Our approach
Our team, led by Michał Wiśniewski, spent 4 days on the warehouse floor itself, measuring travel time between racks with a stopwatch. We noticed that the most frequently bought mortar bags were 42 meters from the packing zone, forcing unnecessary walks. We made a movement heat map and calculated new routes. No fluff about visions – we simply trained the 9-person team on using new scanners and showed them how every minute of error affects their bonus. We don't just advise; we check if people actually stick to the new rules.
The solution
We implemented an EAN-13 verification system at every stage of packing. Now the warehouse worker must scan the item before putting it in the box – if the code doesn't match, the terminal beeps and blocks the process. We also changed the physical layout of the hall: 247 most popular products were moved to the so-called 'fast zone,' which shortened the walking distance by 310 meters per pallet. Additionally, we introduced a 'double eye' rule for orders above 4,500 PLN, where a second person checks goods compliance with the invoice before loading onto the car.
Results
After three months, the number of complaints dropped from 89 to 47 per month, which significantly relieved the customer service department. Employees stopped running pointlessly around the hall, and the company saves concrete amounts on fuel and return couriers.
Timeline
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March 2024Baseline audit and measurement of 42 warehouse paths.
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April 2024Rearranging 12 rows of shelves and reorganizing Zone A.
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May 2024Installing Zebra terminals and code verification testing.
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June 2024Full launch and training for 9 employees.
"To be honest, I thought it was the people's fault, not the system. Solvium showed us that warehouse workers were simply losing time on errors that were unavoidable without scanners. Now there is peace."