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Picking errors usually happen when items are mixed, placed in the wrong zone, carried by hand or moved without clear separation. In warehouse operations, order picking is often one of the most labor-intensive processes, and industry research commonly estimates that picking can account for more than 50 percent of warehouse operating costs.

Warehouse fatigue often comes from repeated lifting, carrying, pushing, pulling and walking between storage, packing and loading areas. OSHA notes that heavy loads, awkward posture and repetitive tasks can increase the risk of musculoskeletal disorders, while ergonomics can reduce muscle fatigue and improve productivity.

Warehouse efficiency is often measured by how quickly products move from receiving to storage, picking, packing and shipping. While many companies focus on software and automation, material handling equipment remains one of the most direct factors affecting daily productivity.