New to the site and looking for some suggestions. I am the newly appointed Inventory Manager for a rather large warehousing account for a 3PL company. We are forced to use our customer's software (SAP) and it is not the best for inventory control. Picking is manually done using paper pick lists which is one of the biggest root causes of our inventory problems. We audit shipments being loaded and shipped to certain customers but not many so a lot of picking errors do not get caught.

We're in the process of logging the errors when the customers notify us of discrepancies and we tie them back to specific picker. Holding them accountable will help but I'm looking for ways to make it dummy-proof.

We are a case-picking operation and ship anywhere from 50k-80k cases out the door each day.

Curious to hear what kind of practices you all use to ensure accurate picking in a manual operation....