of inventory errors originate from human mistakes
of recurring errors: picking, data entry, location
What the research says
According to Logimax WMS, the causes of inventory inaccuracy are well documented: manual data entry errors (wrong quantity, wrong SKU), picking errors (wrong item pulled), location errors (product stored in the wrong place), and confusion during receiving. These errors are structural: they occur even with trained, diligent teams, simply because the manual process exposes too many steps to fatigue and inattention.
The three main sources of human error
Argo Software identifies three main vectors of stock discrepancies. First: data entry errors — a quantity typed in haste, a misread SKU, an inverted unit (box vs unit). Second: picking errors during order preparation, where a similar but incorrect item is pulled. Third: location errors during put-away, which create gaps between what the system shows and what is physically present. Each of these vectors is nearly impossible to eliminate without automation.
A documented improvement model
A study published on ResearchGate (2017) proposes a model for improving human errors in warehouse operations. The authors emphasize that the desynchronization between actual and system stock is the direct consequence of these accumulated errors. Their main conclusion: reducing human interventions in data entry and verification steps is the most effective lever for improving accuracy. Technological solutions (scanners, WMS) divide the error rate by a factor of 5 to 10 compared to manual processes.
Why it's hard to fix without the right tool
The problem of human errors is not a training or motivation issue. It's a process issue. An operator who enters 200 lines per day will statistically make several errors, even with the best intentions. Without automatic confirmation tools (scanning, software validation), these errors go unnoticed until they generate a stockout, an incorrect order, or a catastrophic annual inventory.
Manual stock management places human error at the heart of the process. This is not inevitable: modern WMS tools like ApsionScan dramatically reduce this risk by requiring scan confirmation at every operation, eliminating free data entry steps.
This summary is a free reformulation of works by Logimax WMS, Argo Software, and ResearchGate, created for informational purposes. Key ideas are attributed to the cited authors. Consult the original sources for complete analyses.
Original sources
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Human Errors in Warehouse Operations: An Improvement Model
Parama Kartika Dewa, Nyoman Pujawan, Iwan Vanany, 2017
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