Modern technologies such as wearables not only promise efficiency, but also zero error picking. But what does this look like in practice? And which strategies are market leaders already using successfully today?
Zero error picking describes a logistics process in which targeted measures and technologies are used to virtually eliminate human error. The aim is to ensure that exactly the right item in the right quantity is picked at the right time during order picking - without the need for checks or correction loops.
This principle is particularly relevant for industries with a high variety of items, sensitive supply chains or a high turnover frequency, such as e-commerce, spare parts logistics or food wholesale.
Even well-trained employees make mistakes, especially when processes are manual or there is a lack of visual guidance. Common causes:
Paper-based picking lists where the wrong lines are ticked off
Unclear storage locations or unclear item labeling
Distraction in the workflow, e.g.e.g. by constantly reaching for scanners or handhelds
Lack of feedback in the event of incorrect removal (e.g. no warning signal)
However, these sources of error can be eliminated with the right digital tools.
The simpler the process, the lower the probability of errors. Clear paths, logically structured storage zones and intuitive picking routes are the basis.
Wearables, i.e. portable devices such as scanners, displays or gloves, ensure that information is directly on the body. This means
Hands remain free
Routes become shorter
Feedback is provided in real time
Example: A light display shows the picker directly on the back of the hand or storage location where the next pick will take place, in color, conspicuously and clearly.
Flashing LEDs, vibration signals or display messages provide immediate feedback as to whether the correct item has been picked, even before an error occurs.
Systems that are connected to the warehouse management system (WMS) enable direct bookings, validations and automatic checking mechanisms, without any paper or intermediate steps.
Many leading logistics companies now rely on a combination of ergonomic wearables, light guidance and smart software logic.
They follow a clear principle: people remain at the center, but the technology takes over error prevention.
A real-life example:
HAKA Kunz, a manufacturer of sustainable cleaning and care products, has optimized its warehouse logistics with wearables. Thanks to the clear visual, acoustic and haptic feedback and wearable with touch display worn on the back of the hand, the company has been able to reduce picking errors to zero since day one and at the same time significantly increase the speed of the picking process.
Thanks to direct communication between the worker and the system, errors are detected at an early stage and prevented before they occur. For HAKA Kunz, it was crucial that the solution not only works reliably, but is also intuitive and popular with warehouse employees.
Zero error picking is not a distant dream, but an achievable goal if the right measures are taken. Wearables play a key role here because they simplify processes, shorten paths and safeguard decisions.
Whether you're a small warehouse or a large mail order company, investing in smart, ergonomic technologies today not only prevents errors, but also secures your competitiveness for tomorrow.