We took some action on it and totally revamped our order picking/checking/packing so hopefully issues/errors can be minimized..
I have a suggestion on that. Your item numbers have some issues that would make them tough to pick. Just one example: Items 3152 and 3125. They are both stainless dual coils. They are different sizes and one comes with a tip, but they are both stainless DCs from the same manufacturer and those numbers are easy to swap.
If I were a runner/picker in your warehouse, I'd screw that one up repeatedly. Very similar items with very similar packaging need to have very dissimilar ID numbers.
I worked in a grocery warehouse for a few years. It often cropped up that mispicks would get out of hand during summer sales of soda pop and canned goods and again in the fall when pasta and top ramen went on sale. The bosses always held up the housewares dept as an example because their mispick rate was always lower than everyone else. -
One of the housewares guys had a medical issue and I took his job for two months. My personal mispick rate dropped from around my normal ~1% to ~.3% while I was there. --- That made me think a lot. I went to a department I'd never worked before and where I was actually picking more items per day (generally smaller items, but about 20% more total) and my mispick rate dropped to less than half what it had been in the job I had been doing for a long time and where i was familiar with almost every item.
I looked long and hard at the differences in departments. - It was the item numbers. For example, a 4 pack of 60w lightbulbs was item 62667-0014 and a 4 pack of 100w bulbs from the same manufacturer was item 55157-1132. They weren't even close to the same number. Almost everything in housewares was like that. Further investigation revealed that the three main suppliers of our housewares items did this on purpose to reduce inventory problems and mispicks on their end. They re-labeled almost everything or stamped their own numbers on just about everything that couldn't be re-labeled. --- General grocery suppliers used a different inventory system and did not do that. Their item identification numbers were all similar for similar products.