Jul 01, 2025

The global warehousing and distribution market is on pace to hit $1.73 trillion by 2030¹, over an 8% increase from 2025. In this fast-growing climate, distribution center efficiency isn’t just a best practice, it’s a survival strategy. This is most evident in shipping and receiving processes, where delays, miscounts, and documentation errors can ripple across the entire supply chain. As e-commerce booms and customer expectations for speed and accuracy increase, the pressure on distribution centers has never been higher.

Fortunately, technology has evolved to meet today’s challenges. Mobile computing devices, barcode scanners, and on-demand label printers have become mission-critical tools in the fight for speed, accuracy, and DC workflow optimization. In this post, we explore the five biggest challenges in modern shipping and receiving workflows, and a roadmap to transforming warehouse chaos into control with mobile technology and barcoding solutions.

Challenge #1: Inventory Inaccuracies

Inventory accuracy is the foundation of any effective supply chain, yet it’s one of the most common challenges in warehouse operations. A single mistake at the receiving dock, whether it’s a missed scan or data entry error, can cascade into order fulfillment delays, and angry customers. With the rise of SKU proliferation and tighter customer tolerances, the room for these kinds of errors is shrinking.

According to a study by Auburn University, the average inventory accuracy in retail and distribution environments is approximately 63%², a staggering number when you consider how reliant the rest of the supply chain is on this data. Manual documentation, spreadsheet-based logs, and paper tickets simply can’t keep pace with the complexity and speed of modern logistics, but today’s distribution center automation tools can!

Solutions:

Mobile Barcode Scanners – Barcode scanning technologies enable instant data collection, and data access anywhere in the warehouse. By capturing real-time inventory information, and lot data, businesses can eliminate manual entry and see significant improvements to inventory accuracy.

Mobile Printers – Purpose-built printers for mobile warehouse workers allow high quality labels to be generated and affixed instantly, anywhere on the DC floor. Instant label printing at the point of application saves valuable time and reduces documentation mismatch. 

RFID Solutions – In higher volume settings, larger DC operations may utilize RFID for inventory accuracy. This technology provides highly accurate counts via RFID chips and readers. Automated technologies like these improve overall distribution center efficiency by delivering lightning-fast scanning of larger batches of goods.

Challenge #2: Dock Congestion 

The loading dock is one of the most critical (and sometimes chaotic) touchpoints in any warehouse. It's where product flows in and out, where timing is tight, and where even minor delays can disrupt schedules. Yet, many facilities still operate with outdated layouts and a lack of visibility into both inbound and outbound loads.

Dock congestion and disorganization creates a domino effect that impacts shipping times, and carrier efficiency. Mismanaged shipping and receiving processes can often cause hours of delays. For high-throughput facilities, these delays can add up to massive productivity losses.

Solutions:

Voice Picking – Voice picking technologies streamline shipping and receiving processes by eenabling hands-free, eyes-up workflows. This helps automate manual tasks and take the guesswork out of picking processes, resulting in up to 99.9% accuracy.

Rugged Handheld Scanners – Built for warehouse demands, rugged, flex-range barcode scanning solutions feature ergonomic designs that reduce worker fatigue in high-pressure loading and unloading workflows. Docking teams can access and collect data instantly without cumbersome manual processes.

Cross-Docking Technologies – Cross-docking is a practice in logistics of receiving goods in a warehouse and shipping them without putting them into inventory. Cross docking solutions allow distribution teams to streamline sorting and repacking, reducing labor costs, storage demands, and improve turn-around times.

Challenge #3: Labor Challenges & Human Error

A tight job market, rising wage pressures, and high turnover have left many distribution centers understaffed and overextended. When labor is in short supply, distribution center efficiency, accuracy and speed suffer.

According to the U.S. Bureau of Labor and Statistics, up to 70% of warehouse operational costs are labor-related. Add to that the fact that manual data entry and visual checks are inherently error-prone, and it’s easy to see why warehouses are increasingly turning to automation—not to replace workers, but to empower them.

Solutions:

Faster Onboarding with Voice Picking – Voice picking technologies reduce training time and help workers get up to speed faster by adapting to speech/language preferences.

Wearable Scanners – wrist or ring mounted devices provide an ergonomic way to scan barcodes near-and-far without the burden of carrying a device. Wearables improve shipping and receiving operations as well as worker satisfaction.

Mobile Computing & Barcode Scanners – Today’s cutting-edge mobile computers and barcode scanning solutions reduce data entry task and speed up common warehouse workflows. Built-in validation features help prevent common worker errors such as wrong SKU, or quantity.

Challenge #4: Receiving and Put-Away Bottlenecks

When inbound shipments arrive faster than they can be processed, the entire operation backs up. Items sit on pallets waiting to be scanned, docks become congested, and product flow slows down. In high-volume environments, even minor inefficiencies in receiving can result in hours of lost productivity over the course of a day.

According to MHI, inefficient receiving and put-away processes was the third biggest challenge cited by distribution center managers in 2024. Put-away delays are especially damaging when they result in misplaced or improperly stored goods. Without distribution center automation tools, or a real-time systems to track where items are being stored, pickers often waste time hunting for inventory, and accounting for discrepancies.

Solutions:

Automated Put-Away Guidance – Guided put-away directions can be sent to mobile computers and tablets on the receiving dock, indicating the exact location for accurate put-away.

Cross-Docking Workflows – Using barcode scanning, instant data can direct certain products or items straight from receiving to shipping, reducing unpacking times, and can ultimately improve shipping and receiving times.

On-Demand Labeling – Mobile printers can be worn at the hip and enable workers to print item or pallet labels right at the point of receipt, rather than wasting time walking to static printers.

Challenge #5: Poor Visibility

In our digital-first world, operating without real-time data is a recipe for disaster. From visibility into order status, to dock activity, and employee productivity, a lack of visibility makes it impossible to make informed decisions. Yet, according to Zebra Technologies’ 2023 Warehouse Vision Study³, 82% of operations leaders say they lack real-time visibility into their warehouse performance.

Solutions:

Barcode-driven Traceability – Barcode scanning solutions allow for real-time digital tracking from receipt to delivery to customers. Reliable tracking can improve brand loyalty, and the overall customer experience, and gives businesses a clear window into their operations.

Accurate Reporting and Auditing – Accurate reporting allows warehouse managers to see who scanned what, and when, all in real-time. They also create a “breadcrumb trail” of item history, essential for regulatory compliance, traceability, and recalls.

RFID Solutions – RFID can deliver more than inventory accuracy. Automatically tracking goods as they move through receiving, storage, picking and shipping allows for real-time traceability, recording precise item locations and movements.

How Heartland Delivers End-to-End Warehouse Solutions

Tackling the complex challenges of shipping and receiving requires more than just hardware or software. True distribution center efficiency demands a strategic partner who understands the operational realities of distribution environments and can implement scalable, future-ready solutions. That’s where Heartland USA excels.

Heartland doesn’t just sell mobile devices or barcode scanners, we design and deliver fully integrated workflows tailored to your warehouse layout, inventory demands, and throughput goals. From rugged handhelds and mobile printers to advanced barcode/RFID technology, Heartland connects the dots so your technology can deliver maximum productivity.

Are you ready to boost order accuracy, streamline put-away, or gain real-time visibility into your operations? Heartland has the expertise, partnerships, and proven methodologies to make it happen. Contact us today to get started.

[1] Source:  https://www.grandviewresearch.com/horizon/outlook/warehousing-market-size/global

[2] Source: https://rfid.auburn.edu/papers/inventory-accuracy-whitepaper/

[3] Source: https://www.zebra.com/us/en/cpn/warehousing-vision-study.html