99.6% pick accuracy; 82% fewer chargebacks
"Our pick accuracy was 94%, which sounds good until you realize that a 6% error rate meant 50+ wrong shipments per week and angry customers calling. ThunderStaff built a pick-and-pack validation system that sequences picks by zone, validates SKU and lot by barcode scan, and flags mis-picks before they ship. Accuracy went to 99.6%. Chargebacks dropped 82%. Our warehouse manager said it was the first time in 12 years he did not dread Monday morning."
The Problem
94% pick accuracy meant a 6% error rate — 50+ wrong shipments per week and angry customers calling.
The Solution
ThunderStaff built a pick-and-pack validation system that sequences picks by zone, validates SKU and lot by barcode scan, and flags mis-picks before they ship.
Key Results
Build Your Process Blueprint
See exactly where you're losing money and what automation looks like for Free.
View Talk Track
Industrial Distribution Company
Industrial & Agricultural Distribution • Billings, Montana • 22 Warehouse Staff
The Problem
94% pick accuracy meant a 6% error rate — 50+ wrong shipments per week and angry customers calling.
The Solution
ThunderStaff built a pick-and-pack validation system that sequences picks by zone, validates SKU and lot by barcode scan, and flags mis-picks before they ship.
Key Results
“Our pick accuracy was 94%, which sounds good until you realize that a 6% error rate meant 50+ wrong shipments per week and angry customers calling. ThunderStaff built a pick-and-pack validation system that sequences picks by zone, validates SKU and lot by barcode scan, and flags mis-picks before they ship. Accuracy went to 99.6%. Chargebacks dropped 82%. Our warehouse manager said it was the first time in 12 years he did not dread Monday morning.”
We map your most painful process end-to-end and show you exactly where the waste is — and what the ROI looks like.