Four WMS features that reduce product loss

Product loss compounds quickly in a warehouse. A single missing item can delay an order, force you to pull products from another order to stay on schedule and accelerate unnecessary resupply purchases.

It’s a critical issue that ripples throughout the supply chain. Many warehouses turn to their warehouse management system to enhance inventory control and reduce losses. Utilizing advanced WMS functionality can unlock a smarter, more efficient approach to minimizing errors and reducing costly waste.

Smart packing limits prevent damage and spills

The lifts, carts, and other materials your warehouse workers use each day are designed to handle specific loads. A system with intelligent warehouse management functions helps ensure workers don’t overload carts, reducing the risk of spills, breakage, and damage to equipment or products.

By considering weight distribution, co-packing rules, and stacking limits, a WMS prevents excessive stacking that could crush products underneath. Some systems also optimize picking speed to prevent overloading, making the warehouse safer and more efficient.

Optimized warehouse layouts minimize product loss

One of my favorite features of a WMS also plays a significant role in product loss reduction - reorganizing the warehouse.

By analyzing workflows, it can recommend better storage arrangements, reduce congestion, and ensure workers have enough space to operate safely. For warehouses using RFID or BLE tracking, the system can also pinpoint misplaced goods in real time. This reduces lost inventory and ensures products reach the correct workstation without delays.

Additionally, scheduling tools in a WMS can help manage cleaning and maintenance, preventing clutter-related product damage.

Reducing manual handling lowers the risk of errors

Each manual touchpoint increases the likelihood of product damage. A WMS reduces human error by automating processes like barcode scanning, pallet tracking, and conveyor-based transport between workstations.

Advanced tools such as accumulation conveyors hold products until the next station is ready, preventing misplacement and reducing the risk of damage. These improvements keep inventory moving smoothly while minimizing losses.

Continuous tracking strengthens security and reduces waste

Sometimes product loss means theft. We touched on the ability of a WMS to track equipment, components, and more through a variety of sensors.

A WMS with real-time tracking monitors inventory, equipment, and personnel using RFID chips and sensors. If a product is tampered with or moved unexpectedly, the system sends an alert immediately.

RFID-enabled employee badges add another layer of security by tracking who is near valuable inventory. Additionally, requiring check-ins at each stage of the supply chain reduces unauthorized handling and shrinkage.

For warehouses handling perishable goods, continuous tracking ensures FIFO (First In, First Out) compliance, reducing spoilage by prioritizing the oldest stock.