Why it is essential to assess your warehouse operations constantly (and not only when things go wrong)

As a warehouse manager or operations director, you are constantly facing challenges in managing your warehouse operations. From ensuring timely and accurate order fulfilment to maintaining efficient workflow and minimizing costs, there is a lot on your plate.

In such a dynamic and fast-paced environment, it is essential to constantly assess and evaluate your warehouse operations to identify areas of improvement and ensure that your warehouse is operating at its best. But when should you consider conducting an assessment of your warehouse operations?

When to consider an operational assessment of your operations?

At all times

Even if you are not currently experiencing any challenges or changes in your warehouse operations, it is still important to conduct regular assessments to identify potential areas for improvement and keep your operations running smoothly. Just like any other business, your warehouse operations are constantly evolving and it is essential to stay ahead of the curve and ensure that your operations are up-to-date and aligned with your business goals.

Regular analysis of operational data can help greatly to keep one’s finger on the pulse at all times. The quicker you discover the inefficiency, the quicker you can solve it and the lower the total damage of that inefficiency will be. However, most warehouses don’t use the vast amounts of data they have at their disposal, which is a missed opportunity. This is often caused by missing data analysis capabilities within the team, WMS systems lacking analytics- or dashboarding functionality or warehouses simply not using dashboarding or analytics functionality they already have at their disposal.  

The quicker you discover the inefficiency, the quicker you can solve it and the lower the total damage of that inefficiency will be

We therefore strongly advise to assess what technologies and skills you already have at your disposal and think about how you can tap into this gold mine. In case you don’t want or are not able to do this by yourself, consider partnering with a technology company.

In case you have data analytics capabilities available, there are two other moments when it is essential to take a deep-dive into your operations.

When you are experiencing problems or challenges in your current operations.

One key reason to consider a deep dive assessment of your warehouse operations is when you are experiencing problems or challenges in your current operations. For instance, if you are facing frequent errors or inaccuracies in your order fulfilment process, or if you are seeing a rise in shipping and handling costs, it may be time to assess your operations and identify the root cause of these issues.

When operations change significantly

Another reason to consider an assessment is when you are experiencing a significant increase in your warehouse operations. Whether it is due to an increase in demand for your products, or the addition of new products or services, a sudden increase in warehouse operations can put a strain on your current processes and systems. In such cases, an assessment can help you identify areas where you need to improve or expand your operations to keep up with the increased demand.

When you’re planning to implement new technologies or systems

Additionally, if you are planning to implement new technologies or systems in your warehouse, an assessment can help you determine the potential benefits and drawbacks of these technologies and ensure that they are aligned with your overall warehouse operations goals. By conducting an assessment before implementing new technologies, you can avoid potential problems and ensure that your warehouse operations are optimized for the new systems.

How to conduct an operational assessment?

As stated before, it is important to first gather data on your current operations. This can include metrics such as order fulfillment time, inventory accuracy, and shipping accuracy. You can also gather data on your warehouse layout and the equipment and technology currently in use.

Once you have collected this data, you can begin to analyze it to identify any areas for improvement. For example, if you find that your order fulfillment time is longer than industry benchmarks, you may need to reevaluate your warehouse layout and processes to increase efficiency. Similarly, if you find that your inventory accuracy is lower than desired, you may need to implement new technology or processes to improve accuracy.

In addition to analyzing data, it is also important to conduct on-site observations of your warehouse operations. This can help you identify any bottlenecks or inefficiencies in your processes, as well as potential opportunities for improvement. For example, you may observe that a particular area of the warehouse is consistently congested, leading to slower order fulfillment times. In this case, you may want to consider implementing new processes or technology to improve flow in that area.

Develop a plan to address areas for improvement

Once you have identified areas for improvement, it is important to develop a plan to address them. This may include implementing new technology, reevaluating warehouse layout, or implementing new processes. It is also important to regularly monitor and evaluate the effectiveness of these improvements to ensure that they are having the desired impact.

Involve your team

One key aspect of conducting an operational assessment is involving your team in the process. By engaging your team in the assessment and improvement process, you can foster a culture of continuous improvement and ensure that your team is invested in the success of the warehouse. This can also provide valuable insight and ideas from those who are directly involved in the day-to-day operations of the warehouse.


In conclusion, conducting an operational assessment of your warehouse helps to identify areas for improvement and ensures that your operations are running efficiently and effectively. By gathering data, analyzing it, conducting on-site observations, and involving your team in the process, you can develop a plan to address any areas for improvement and monitor the effectiveness of those improvements. Regularly conducting operational assessments can help you stay ahead of potential issues and continually improve the operations of your warehouse.

As with all solutions that rely on data, there's one core thing to keep in mind: garbage in, garbage out. You'll therefore have to make sure that the data you measure and the data that is stored in your WMS is accurate. That's where Powerhouse AI can help. We make sure that your inventory data is always right. Explore our AI-enabled application to automatically count and check your inventory to streamline your inbound, outbound and stocktaking processes. Get in touch for a chat.

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