How to Reduce Wrong Shipments Using Smart Scanning Solutions

Wrong shipments are one of the most painful problems in warehouse operations. A single wrong pick or wrong label can create:

• Customer complaints
• Return freight costs
• Repacking effort
• Negative ratings
• Delayed revenue

With increasing order volumes, traditional manual checking is no longer enough. This is why smart scanning solutions and SAP EWM mobility tools are becoming essential for every warehouse.

This blog explains — in simple language — how modern scanning technology helps reduce wrong shipments and improve accuracy from Day 1.

Why Wrong Shipments Happen (Root Causes)

Before fixing the problem, we must understand why it happens.

Common reasons include:

• Operators picking from wrong bins
• Wrong SKU scanned due to faded barcode
• Multiple similar-looking products
• Manual keying mistakes
• Poor bin labeling
• Rush during peak hours
• Inexperienced workers

Most of these issues come from human error — and smart scanning solutions eliminate exactly that.

What Are Smart Scanning Solutions?

Smart scanning solutions use:

• AI-powered scanning apps
• Camera-based scanning
• Error validation rules
• Real-time SAP EWM checks
• Voice + visual guidance
• Barcode + QR + RFID readers

They work on rugged devices, Android mobiles, tablets, or wearable scanners — making them extremely flexible.

How Smart Scanning Helps Reduce Wrong Shipments

Real-Time SKU Verification with SAP EWM

When a worker scans a product:

• The device instantly checks with SAP EWM
• Confirms if the SKU matches the pick task
• Confirms correct batch, serial number, HU, or bin
• Alerts if the wrong item is scanned

This avoids 90% of wrong picks.

Smart Error Alerts

If the operator picks the wrong:

• Material
• Batch
• Serial
• HU
• Quantity

The scanning system shows:

• WRONG ITEM
• WRONG BIN
• WRONG QUANTITY

These alerts prevent mistakes before they move to the next step.

AI Vision-Based Scanning 

This is the future.

AI camera tools can identify products using:

• Shape
• Size
• Color
• Printed text

Even if the barcode is damaged or missing, the system identifies the product.

This is extremely useful in:

• Retail
• Healthcare
• Apparel
• FMCG

Two-Step Validation During Pack & Ship

Smart scanning ensures:

At Picking

Worker picks item → scan → SAP validates

At Packing

Before sealing carton → scan again → correct order validation

This double check ensures100% accuracy.

Smart Routing: Correct Bin, Every Time

Scanning apps can guide workers to the correct bin with:

• Arrows
• Maps
• Voice instructions
• Vibrations when near the bin

This avoids:

• Picking from similar bin numbers
• Confusion in bulk storage areas

Auto-Capture of Batch, Expiry & Serial Numbers

No typing needed.

The scanner automatically reads:

• Manufacturing date
• Expiry date
• Batch code
• Serial number
• Lot info

This eliminates manual entry errors.

RFID Scanning for High-Speed Validation

RFID is the fastest method when dealing with:

• High-volume picks
• Pallet movements
• Bulk orders

RFID can scan 50–200 items in seconds, drastically reducing wrong dispatch.

Digital Proof Before Shipping

Smart scanning apps can capture:

• Photo of picked items
• Photo of packed carton
• Signature from quality checker

This creates a digital audit trail linked to SAP EWM.

If customer raises a complaint → warehouse already has proof.

AI + Smart Scanning = Zero Errors

AI learns from past mistakes:

• Which product is often picked wrong
• Which worker makes frequent errors
• Which zone causes confusion
• Which bin mapping is incorrect

Based on this, AI suggests:

• Better slotting
• Better walking routes
• Better labeling
• Automatic alerts

Benefits of Smart Scanning in Warehouses

• 90–98% reduction in wrong shipments
• Faster picking and packing
• New workers become productive in days
• Zero dependency on memory
• Accurate tracking of batch + expiry + serial
• Real-time validation with SAP EWM
• Fewer customer complaints
• Higher customer satisfaction
• Reduction in return costs

Who Should Use Smart Scanning?

Smart scanning is ideal for:

• E-commerce warehouses
• 3PL / logistics companies
• Retail distribution centers
• Pharma and medical warehousing
• Automotive parts
• Apparel & footwear
• Food & FMCG

Conclusion

Wrong shipments are not just mistakes — they are losses.

They cost money, time, and reputation.

Smart scanning solutions combined with SAP EWM help warehouses achieve:

• Error-free picking
• Accurate validation
• AI-powered decision-making
• Faster operations
• Better customer experience

Warehouses that upgrade now will have a huge advantage over competitors still relying on manual processes.