🇧🇷Brazil

Custo Excedente por Reprocessamento Devido a Picking Errors

2 verified sources

Definition

Manual order picking in Brazilian warehouses generates picking errors (wrong SKU, short shipment, damaged item in pack) at rates of 2–5% in high-volume environments. Each error cascades: customer return, reverse logistics, exception handling, re-picking, re-packing, re-shipment. The cost of rework (labor, materials, shipping) is 2–5× the original picking labor cost. In reverse logistics, errors create additional storage, customs, and handling complexity.

Key Findings

  • Financial Impact: Per picking error: R$50–R$300 (rework labor + return shipping + re-shipment). At 2% error rate for 50,000 units/month: 1,000 errors × R$150 avg = R$150,000/month (R$1.8M annually).
  • Frequency: Per picking error; ongoing in manual operations
  • Root Cause: Manual picking without barcode verification; high-speed operations trading accuracy for throughput; inadequate quality checks at pack station.

Why This Matters

The Pitch: Brazilian 🇧🇷 warehouses waste R$50K–R$500K+ annually on rework, returns processing, and customer compensation due to picking inaccuracy. Barcode-driven picking reduces error rates to <0.5%, eliminating rework costs.

Affected Stakeholders

Order pickers, Quality control staff, Packing station operators, Returns/RMA processors, Warehouse management

Deep Analysis (Premium)

Financial Impact

Financial data and detailed analysis available with full access. Unlock to see exact figures, evidence sources, and actionable insights.

Unlock to reveal

Current Workarounds

Financial data and detailed analysis available with full access. Unlock to see exact figures, evidence sources, and actionable insights.

Unlock to reveal

Get Solutions for This Problem

Full report with actionable solutions

$99$39
  • Solutions for this specific pain
  • Solutions for all 15 industry pains
  • Where to find first clients
  • Pricing & launch costs
Get Solutions Report

Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

Erros de Classificação Fiscal em NF-e Gerados por Picking Incorreto

SEFAZ penalty: R$500–R$10,000+ per rejected NF-e document (logic estimate based on Customs Authority discretionary penalties). Typical monthly impact for 50+ shipments: R$5,000–R$25,000 in penalties + delayed cash flow.

Multas de Alfândega por Erros de Picking em Importações

Customs demurrage/storage: R$50–R$500 per TEU per day (typical: R$100–R$300 daily). Fines for inventory discrepancies: R$1,000–R$50,000+ per incident (logic estimate). Dispute resolution and customs broker intervention: R$500–R$5,000 per case.

Não-Faturamento de Serviços Adicionais em Picking/Packing

Typical revenue leakage: 3–8% of picking/packing service revenue per month. For a 50,000-unit/month warehouse at R$5/unit service fee: R$7,500–R$20,000 lost monthly (R$90K–R$240K annually).

Multas e Sanções por Não Conformidade em Armazenamento de Materiais Perigosos

Estimated: R$ 10,000–50,000 per violation (based on typical Brazilian NR enforcement); single facility can face 5–15 violations per inspection. Shutdown costs: R$ 50,000–500,000/day lost revenue. License revocation: total business loss.

Custos Operacionais Elevados em Infraestrutura de Conformidade

Estimated: R$ 1,000–3,000/month per 1,000 m² for infrastructure maintenance; R$ 40–80/hour for manual compliance documentation (estimated 15–25 hours/week per facility). For medium warehouse: R$ 80,000–150,000/year in preventable overhead.

Perdas por Incidentes, Derramamentos e Reclamações Decorrentes de Não Conformidade

Per-incident: R$ 100,000–1,000,000+ (cleanup, regulatory fines, worker comp). Preventable incidents: estimated 2–5 per year per facility lacking automated monitoring.

Request Deep Analysis

🇧🇷 Be first to access this market's intelligence