Why barcode scanning matters
Manual data entry introduces errors at every step: receiving discrepancies, mislocated inventory, mispicks, and shipping mistakes. Barcode scanning reduces these errors by 90%+ while speeding up operations. Every scan creates an audit trail linking who did what, when, and where. Teams that scan first spend less time fixing problems and more time fulfilling orders.
Scanner types and selection
**Handheld laser scanners** work well for stationary workstations and high-volume scanning. **2D imagers** read QR codes and damaged barcodes better than lasers. **Mobile computers** (Zebra TC series, Honeywell) combine scanning with a screen for directed workflows. **Smartphone cameras** work for basic scanning but struggle in low light or with worn labels. For warehouse use, invest in ruggedized devices with all-day battery life.
Barcode symbologies explained
**UPC/EAN** are retail product barcodes—12 or 13 digits encoding manufacturer and item. **Code 128** encodes alphanumeric data for location labels and license plates. **Code 39** is an older alphanumeric format still common in manufacturing. **GS1-128** embeds application identifiers for lot, expiry, and serial data. **QR codes** store more data in less space for modern applications. Configure your WMS to recognize the symbologies you use.
Scan-first workflow design
Design workflows that require scanning before any action. Receiving: scan PO barcode, scan item barcode, enter quantity. Putaway: scan item, scan destination location. Picking: scan location, scan item, confirm quantity. Packing: scan order barcode, scan each item, print label. The system should reject mismatches immediately with clear error messages. Never allow manual overrides without supervisor approval and audit logging.
Training and adoption
Start with a pilot group of 2–3 workers for one week. Document common issues and refine workflows before full rollout. Train on the 'why' not just the 'how'—explain that scanning protects them from blame when problems occur. Set accuracy targets (99.5%+) and celebrate teams that hit them. Gradually disable manual workarounds as adoption increases.
Guide
Barcode Scanning in the Warehouse
Give associates the knowledge and tools to scan accurately so every transaction in LollipopWMS is trustworthy.
Barcodes 101
Understand the difference between 1D and 2D codes, quiet zones, and proper label placement. Consistent standards keep scans quick and error-free.
Hardware options
Choose scanners that match your environment: cordless for long aisles, ruggedized for freezer zones, and camera scanners for flexible receiving.
Pair devices with Zebra printers to ensure labels match scanner capabilities.
Labeling do’s/don’ts
- Do keep labels clean and unobstructed.
- Do align label sizes with product packaging.
- Don’t overlap multiple barcodes in one scan zone.
- Don’t reuse faded labels—print replacements immediately.
Review the GS1 concepts in our GS1 barcode guide when you standardize numbering.
Training tips
Build short training loops: demonstrate correct scans, let associates practice with sample orders, then certify them on real workflows with supervision.
Use classroom time to explain how scanning affects inventory accuracy and customer experience.
FAQs
How often should we audit scanners?
Test hardware weekly and replace worn batteries to keep uptime high.
Can we use mobile phones as scanners?
Yes. LollipopWMS supports camera scanning, though rugged devices hold up better for heavy use.
What about label suppliers?
Source labels rated for your environment and test samples before committing to large runs.
Make every scan count
With the right hardware and training, barcode accuracy becomes a daily habit.