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Transitioning to a new Warehouse Management System (WMS) is a high-stakes decision that often triggers concerns regarding downtime, data integrity, and workforce adaptation. As warehouses prepare for 2026 growth, understanding these common hurdles—and the technical solutions that resolve them—is essential for a successful migration. This guide addresses the five primary barriers to adoption and how a high-velocity infrastructure ensures a seamless transition.
Warehouse operators frequently hesitate to upgrade due to perceived risks that can halt operations. These challenges typically include:
To clear these hurdles, a structured implementation strategy is used to prioritize data density and entity clarity.
In the competitive eCommerce landscape, staying stagnant with manual workarounds is often more costly than the transition itself. Moving to a high-velocity WMS converts your warehouse from a cost center into a growth engine by providing Labor Efficiency and ROI through automated routing and reduced authentication friction.
Because the platform is built for the floor worker, features like Workforce Hero allow seasonal temps and new staff to be authenticated and productive in under an hour.
No. High-velocity infrastructure increases visibility by providing Total Real-Time Control. Managers can monitor exactly what is in the Hospital queue and track replenishment in real-time from a single dashboard.
Before going live, a ground-up audit is performed using cycle counting tools. The system's architecture ensures that every movement on the floor is synchronized with sales channels instantly, maintaining 99.9% accuracy.
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Picture a packer at Peak Season. A box is in front of them, a product in each hand, and somewhere on a cluttered desk there's a mouse they need to find to confirm the order. They look down. They hunt. They click. Then they do it again. Thousands of times a day.
That moment of friction is small. But it is never just one moment. Multiply it across your entire pack line, across an entire shift, and you are looking at a measurable and largely invisible drag on your total throughput.
Tap-to-Pack is a purpose-built hardware controller designed by ShipHero to eliminate digital friction at the packing station. It connects via USB-C, requires no drivers or additional software, and syncs automatically with the ShipHero WMS packing app. This new system is now available at the ShipHero Store.
Instead of navigating a screen with a keyboard and mouse, packers execute every high-frequency command — such as selecting box sizes, printing labels, finalizing orders, flagging exceptions — with a single physical tap on one of eight programmable buttons.
Key specifications:
Most warehouses are running 2026 operations on 1990s peripheral standards. The keyboard and mouse were designed for spreadsheets and emails, not high-volume fulfillment. When used at a packing station, they create three compounding problems:
The problem is not your people. It is the tools you are asking them to use.
Tap-to-Pack introduces a "Rodent-Free" packing standard: a workflow where the packer's hands stay on the product, their eyes stay on the work, and the software fades into the background.
The device guides the packer through two feedback systems:
ShipHero customers running Tap-to-Pack are already seeing a 90% reduction in on-screen interactions and a significant increase in the number of orders packed per hour, without adding headcount or changing their warehouse layout.
One of the hardest challenges in fulfillment is absorbing volume quickly, especially during Peak Season, when temporary staff need to reach target productivity fast.
Because Tap-to-Pack's interface is physical and intuitive, there is almost nothing to teach. Pick up the product, follow the light, tap the button. New packers can reach target productivity in minutes rather than hours.
The system is also modular:
Whether you are a growing DTC brand or a high-volume 3PL, Tap-to-Pack is designed so your hardware never becomes a ceiling on what your team can do.
Tap-to-Pack is a programmable, industrial-grade hardware controller that connects to the ShipHero WMS and allows warehouse packers to execute packing station commands, such as printing labels, selecting boxes, and completing orders. All with a single physical button press, eliminating the need for a keyboard and mouse.
The device connects via USB-C and syncs automatically with the ShipHero WMS packing app. It is a true plug-and-play solution: no drivers, no background software, and no manual configuration required.
Yes. Buttons are configurable for a range of packing actions, including Print Label, Complete Order, Select Box Size, and the Hospital function, which flags a problematic order and keeps the line moving without stopping to resolve it on screen.
The system is fully modular. Connect up to two additional 8-button hubs to the Main Hub for a total of 24 programmable buttons, supporting even the most complex multi-step packing workflows.
Tap-to-Pack devices require ShipHero Packing App v1.0 or higher. The current release is v1.1.0.
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Imagine running a warehouse where orders are picked quickly, inventory is accurate, and all operations run smoothly without any errors or delays. Thanks to Artificial Intelligence, this can now become a reality with ease.
AI is transforming warehouse management by enhancing efficiency, intelligence, and the ability to meet the rapid demands of today’s eCommerce-driven market.
ShipHero is pioneering this revolution with its AI-powered warehouse solutions, setting new industry benchmarks. This article explores ShipHero’s AI Picking feature, highlighting how it’s transforming warehouse management and enhancing operational efficiency.
The integration of AI technologies, including machine learning, robotics, and predictive analytics, is revolutionizing warehouse operations, driving significant improvements in efficiency, accuracy, and overall performance. These innovations are optimizing processes across various areas, from inventory management to order fulfillment. Below are the key benefits of AI in warehouse management.
A combination of AI technologies is shaping smarter warehouse systems to help revolutionize warehouse management.
ShipHero has taken AI integration to the next level with its AI Picking feature, designed to significantly improve warehouse efficiency. This feature automates the picking process, reducing the reliance on manual labor and enhancing productivity in ways that were once thought impossible.
Let’s dive deeper into how ShipHero’s AI Picking works and the advantages it offers.
AI Picking optimizes warehouse operations in two key ways:
The AI Picking feature delivers a wide range of benefits:
The transformative power of AI extends far beyond just picking. AI is also revolutionizing other aspects of warehouse management, driving improvements in operational efficiency, inventory management, and safety.
AI automates tasks, reducing errors and increasing speed. Automated sorting and real-time inventory tracking ensure accuracy, while real-time monitoring helps managers adapt and ensure timely deliveries.
AI plays a vital role in maintaining accurate inventory levels. By leveraging predictive analytics, AI can forecast demand and optimize stock levels, helping warehouses avoid both stockouts and overstock situations. This leads to better inventory management and fewer disruptions in supply chains.
AI-driven systems can monitor warehouse conditions to ensure safety and compliance with industry regulations. These systems can analyze warehouse data and predict potential hazards before they occur, proactively reducing risks and ensuring a safer working environment.
AI technologies are playing a transformative role in the supply chain and logistics sectors by improving efficiency, reducing costs, and enhancing decision-making.
These intelligent systems effortlessly manage supply chain processes by using data to optimize operations, predict trends, and automate routine tasks. This ultimately reshapes everything, from how goods are moved to stored and delivered.
The future of warehouse management looks promising with greater automation and efficiency, but future warehouse digitization brings challenges, such as high upfront costs and the need for skilled personnel.
AI-powered drones, autonomous robots, and IoT integration are smart warehouse technologies that are revolutionizing warehouse operations. Drones will deliver goods quickly, while robots automate sorting and transportation, thereby reducing the need for manual labor.
IoT and AI integration will enable real-time monitoring and optimization of operations. Smart technology in warehouses is leading to fully automated systems that are faster, scalable, and need minimal human input.
While AI offers immense benefits, businesses must also consider certain challenges. High initial investments in AI technology, data security concerns, and the need for skilled personnel are just a few of the hurdles that must be addressed.
However, with a strategic approach, companies can eliminate the challenges and embrace AI’s full potential to boost accuracy in picking and improve overall warehouse operations.
AI minimizes error by automating tasks like inventory tracking, order picking, and sorting, ensuring greater accuracy and efficiency.
Yes, AI-driven predictive analytics can predict demand, track inventory levels, and improve supply chain efficiency by forecasting needs with greater accuracy to help businesses stay ahead of trends and market fluctuations.
AI solutions are becoming more cost-effective thanks to cloud-based services and subscription pricing models. These options make AI technology more accessible to small businesses, allowing them to take advantage of its benefits without large upfront costs.
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When pallets roll in and loading docks buzz, your warehouse’s receiving process becomes the gatekeeper of inventory accuracy. And if that gate isn’t well-guarded with structure, speed, and oversight, errors slip in.
A mislabeled item here, a damaged shipment there, and suddenly your warehouse faces stock discrepancies, late order fulfillment, or even lost customers.
A warehouse receiving process checklist streamlines receiving operations and ensures compliance across teams, regardless of who’s on shift.
A warehouse receiving process checklist ensures every shipment that enters your facility is properly documented, inspected, and integrated into your inventory system.
Unlike ad hoc or verbal processes, this structured document verifies product condition upon arrival, checks against purchase orders to confirm accuracy, and documents all inspections for future reference.
However, ShipHero’s digital platform already seamlessly integrates this checklist into your system, automating the tracking of goods from the moment they arrive.
Because it captures critical shipment details, a receiving checklist can double as a warehouse audit checklist sample, especially when preparing for performance reviews or inventory audits.
If you’re looking for ways to improve accuracy and accountability, learning how to audit your warehouse with a structured receiving checklist is a great place to start.
Receiving Checklist Sample 1 Â Â Â Â Â
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A well-structured warehouse receiving process checklist is crucial for ensuring accurate and efficient inventory management. Including the mentioned key components helps streamline the process, reduces errors, and enhances overall warehouse performance.
Here’s what you must include in your checklist to maintain control and accountability:
This anchors the entire inspection. By referencing the purchase order (PO) number, warehouse teams can verify the received goods against the original order, ensuring the correct items and quantities are delivered.
Having the supplier’s full details improves accountability. If there’s a delivery issue, this info helps your team evaluate supplier performance and speed up resolution.
Timestamping each delivery helps you review delivery schedules, track shipment delays, and identify potential gaps in receiving coverage.
Here, staff will assess damage or discrepancies, confirm specifications (e.g., size, color), take photos if needed, and record all inspections in case of claims or audits. An effective inventory audit checklist incorporates these inspection protocols to ensure accuracy from the moment goods arrive.
Listing the material name (e.g., product name, SKU, or description) prevents mix-ups during inventory allocation and ensures all items are accounted for. This also helps your Warehouse Management System (WMS) update stock records correctly.
Identifying who delivered and who received the shipment establishes accountability, helps resolve disputes over damaged or missing items, and ensures proper handoff records.
Maintaining proper documentation, such as packing slips, invoices, and bills of lading, facilitates order reconciliation and supports formal audits and record keeping.
A single receiving error often ripples through the entire warehouse. A structured receiving checklist breaks this cycle by establishing clear protocols that coordinate with supply chain operations and create accountability at every step. It drives big improvements in:
This plays out in real operations. A mid-sized clothing retailer had ongoing issues with stock discrepancies during receipt. However, implementing a standardized receiving checklist significantly reduced the number of missing items and stock inaccuracies.
Employees also appreciated having clear instructions to follow, which reduced confusion and helped maintain a smoother workflow during peak delivery periods.
Before drafting your checklist, take a closer look at your existing receiving workflow. Next, identify any inefficiencies and pinpoint areas that could benefit from more structure and consistency.
Choose the data points you’ll need based on your warehouse flow, system integration, and team size. Include only what’s necessary to document key handoff moments.
You can go with paper, but digital formats (via tablets or mobile apps) are easier to scale. Software-based checklists can instantly update records and integrate with your WMS.
Use inventory management platforms or cloud-based tools to build your checklist. For example, ShipHero’s template system allows you to configure fields, set mandatory requirements, and establish workflow rules that guide staff through the receiving process. This makes sure every receiving action is consistent and auditable.
Train staff to make sure every team member follows standardized procedures. This minimizes human error, especially for new or seasonal workers.
Roll out the checklist during a test period. Assign clear roles (e.g., receiver, inspector), gather feedback, and then launch warehouse-wide. Revisit and refine it quarterly to keep up with operational changes.
Your warehouse receiving checklist works even better when paired with these best practices:
Spacing out deliveries helps reduce bottlenecks and allows teams sufficient time to track inventory levels accurately. It also allows for more accurate inspections.
Keep receiving areas clutter-free and near the entrance. This shortens the time it takes to organize storage locations after goods are received.
Invest in equipment such as barcode scanners, conveyors, or forklifts to speed up receiving operations, especially during peak seasons.
Don’t let broken items enter inventory. Flag them, document the issue, and notify procurement so the issue can be escalated quickly.
By leveraging real-time inventory tracking and barcode scanning, you can eliminate the need for manual checklists, ensuring that every received item is accurately logged. ShipHero automates the entire receiving workflow, reducing human errors and speeding up the process.
Customizable receiving workflows allow you to tailor the system to your warehouse’s specific needs, eliminating the need for paper-based checklists. Improve efficiency, accuracy, and consistency, all with ShipHero’s advanced automation tools.
At least annually, or anytime your business introduces a new product line, supplier, or technology upgrades.
Absolutely. Cross-training builds flexibility, enabling teams to cover for absences and maintain efficiency even during peak periods or periods of high turnover.
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ShipHero has distributed teams that are located in the US and Argentina. As we've grown, we've also evolved how we communicate and track tasks.
We share some of our tools and practices with the team at Daxx as we discuss how our teams stay connected and productive.
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Originally featured on Startup Nation‍
Although it may seem like ages ago, many of us remember what an ordeal it was to order products that were unavailable in our local stores. Back then, free shipping wasn’t a thing. Two-day shipping was exorbitantly expensive and reserved for nearly-forgotten birthday presents for the notoriously hard-to-please grandma. And if we needed pedestrian items like lightbulbs or toothbrushes, we would pencil in an immediate trip to Walmart.
Fast forward years later, and we are not only ordering these items online, but Amazon Prime members can expect to receive them in two days with no shipping charge. With Prime, it seems that we can order nearly anything and have these items land on our doorsteps in two days or less. As a result, most of us are guilty of abandoning our carts on other sites after discovering that a) shipping isn’t free and b) it could take five to seven days to receive our orders. Why would we want to pay extra and wait when we can just click on our Amazon app and receive the same product within two days?
This common consumer behavior is supported by the fact that sites offering “free shipping” reduce abandoned carts by 36 percent.
And this means that it is now essential for e-commerce startups to offer free, fast shipping. But while this seemingly unreasonable demand may strike some as an insurmountable challenge, there are several things that entrepreneurs can do to get their orders out quickly and at low cost.
Businesses need to minimize the time between the order received and the shipping label on the box. When dealing with higher volume orders, it’s important to:
As soon as an order is shipped, the email with tracking information should be in the recipient’s inbox. Even if the order itself doesn’t arrive in two days, the knowledge that the product was shipped immediately will influence the shopper’s perception of shipping speed. The positive experience of knowing the order was shipped and the expectation of when the order will arrive increases the possibility of the customer returning for further purchases.
Shipping costs can vary widely among the different carriers, so it benefits business owners to search for the best price. If shipping many orders that are similar, then you may benefit from group shipping methods based on the order type. If handling orders that have a variance of line items, manually rate quoting each order can be time-consuming, which in turn causes orders to become backlogged. Instead, you should choose an optimized platform or program to quickly determine the cheapest option without holding up the order fulfillment process.
It’s even possible to make money using this tactic, especially if the cheapest option among shipping carriers was chosen. Business owners can also review reports on how much was charged for shipping versus how much was actually paid. Typically, most WMS (warehouse management system) solutions provide these shipment reports that chart the historical performance of orders that were shipped out.
Entrepreneurs tend to use paper pick lists to manually fulfill orders. However, this can be a slow and error-prone process, especially if the warehouse is disorganized or pickers are unfamiliar with the warehouse layout. Instead of paper pick lists, go digital. The best way to improve order fulfillment speed is to incorporate barcodes. Barcodes eliminate the guesswork involved in picking and packing orders and drastically reduce fulfillment errors.
If a company has a wide selection of products in a warehouse that has aisles and shelves, it’s extremely important to organize inventory (and if possible) use technology to optimize picking routes. This reduces walk time, and again further eliminates potential mistakes when picking items for orders.
Generally, the cost of shipment is determined by either the weight or the package it’s shipped in (or both, depending on what the order is and where it’s going). While using scales at the time of packing seems like a logical step to determine the weight of the order, there are solutions that allow you to set the weight according to the product’s SKU or the weight and shipping method of each type of shipping container. This method, combined with a rate quote comparison for each shipment, will allow you to achieve a more efficient shipment cost per order when weight needs to be accounted for.
It’s definitely a challenge to beat Amazon’s speed and free shipping; and even if an entrepreneur is running a very efficient operation, it will still be a benchmark to reach. So, what else can a growing e-commerce startup do to compete?
They can add an additional element of experience for customers by personalizing the order. If the owner is using Shopify as the e-commerce store, it’s possible to determine if the customer is a first time customer or has ordered before. Some WMS solutions provide automation rules to set personalized notes or even to add a free product to the order based on what is contained in the order, or the profile of the customer. This personal touch makes a big impact on the customer, and is often more valuable than the expected shipment that arrives a little bit earlier.
After coming up empty handed when searching online for affordable, stylish clothes in a range of sizes, stay-at-home mom Leslie Hall decided to create her own boutique. Shortly after she started filling a 10x10 room in her home with choice inventory, demand for her products quickly soared.
Turned out, countless women just like Hall were eager to find the exact same thing.
In less than four years, ZigZag Stripe exploded and now boasts a proper warehouse facility, three brick-and-mortar stores, and fifty employees. Still family owned and operated, the now-multimillion dollar company has gained a reputation for its fashionable, American-made pieces that flatter a variety of body types.
Of course, it’s due to this reputation that ZigZag’s customers are regular and avid shoppers, many purchasing products multiple times a week. Initially, the growing business had difficulty tracking these orders and often sent them out individually. Using paper print-outs, different warehouse staff would sift through the stock – much of which would be dwindling quickly due to the high demand – and ship each item separately to the same customer’s home. The result, of course, was wasted time and money.
After a particularly harrowing period when the warehouse team struggled to fulfill a huge influx of unexpected orders, ZigZag Stripe decided to use the ShipHero platform. The first day that they used it, they got 200 additional orders out the door. And within the first month, they no longer had the usual fifty or so erroneous orders that resulted from typical human error.
But, the feature that really sealed the deal was the “merge” function.
Now, when customers placed multiple orders in a short timeframe, ShipHero merged them into one. All warehouse staff had access to real-time status of all these orders, so no extraneous shipments were made. And, the warehouse team were able to find the lowest shipping rate for one shipment instead of multiple. As the manager of operations, noted:  for a company with a “cult-like following,” the merge function “has made a world of difference.”
The merge function is just one of the many groundbreaking features that ShipHero uses to help growing businesses fulfill orders and save money on shipments. To learn more about how our platform can address your e-commerce company’s unique needs, please contact us.
Gasoline Pipeline Hack
Good news, gasoline is once again flowing through the Colonial Pipeline. The most recent victim of a ransomware cyber-attack that locked their systems and caused gasoline to stop flowing, Colonial Pipeline Co. was pressured to cough up nearly $5 million in cryptocurrency to hacker group, DarkSide (believed to be based in Eastern Europe, tho it could’ve been Al Gore).
Although at first publicly declaring that they would not pay, the company caved after a few hours, when faced with potential mass shortages of gasoline and jet fuel for major cities along the East Coast of the United States.
What do gasoline pipelines do anyway?
Pipelines transfer crude oil to refineries, so that they can turn them into gasoline, diesel fuel, jet fuel, propane, and more types of oil-based products. Pipelines are also used to transfer gasoline from refineries to major cities. The Colonial Pipeline, in particular, transports gasoline directly to dozens of giant tanks across the Southeast. From there, smaller fuel trucks haul up to 8,000 gallons to individual gas stations.
What’s the damage?
At the time of writing, 74 percent of North Carolina gas stations do not have a fuel supply, and there are shortages in southern Virginia, the Carolinas, Georgia and Tennessee. There is not a shortage of gasoline; rather, refineries are unable to get gasoline to North Carolina and these areas. Due to this, the average gas prices have topped $3 for the first time since October 2014. This has also caused mass panic-buying, long lines, shortages, and worst of all, so many dad jokes about “their gas pipelines being wide open????”.
Supply Chain Outages
CNN has put together a list of product shortages that are plaguing the global economy. From ketchup packets to chlorine, you can find the list here
FedEx E-Commerce Learning Lab
On Thursday, FedEx announced the launch of their new learning program designed to help diverse small business owners develop their e-commerce operations. The program includes free resources for entreprenuers, in addition to providing access to capital, networks and coaching.
Colt 45, I CHOOSE YOU!
Apparently the trading card industry has experienced an immense boon as of late, where trading cards like Sports, Magic: The Gathering, and Pokémon cards have become so sought after that stores can’t keep up with demand. Not to mention, companies that estimate the worth of trading cards have received and graded “avalanches of cards” over the past year.
Despite the long lines of customers waiting hours to buy, Target has recently announced that they will no longer be selling the trading cards, due to a fight that broke out at a Target in Brookfield, Wisconsin. Police were called when a witness saw one man pull a gun. The other man pulled a Charizard card. It was highly effective. Nobody was hurt.
Cool Online Brand of the Week
Call Winnie the Pooh. Since launching only a couple months ago in February 2021, OC Luxury Picnics has disrupted the picnic space, with more than 60 gatherings ranging from a romantic dinner for 2, to an outdoor boba-themed picnic of 20. The founder has since become excited at the idea of starting a fully-fledged business that does not need a brick-and-mortar location. At this time, they only service the lucky folks in Orange County, CA, but this business illustrates the ingenuity of entrepreneurs that turn a side-hustle into a $30,000 venture.
Brexit… not the Harry/Megan saga, the real one.
In this article, we dive into Brexit’s overall effect on your ecommerce business operations, and the 4 things you need to know when shipping to and from the UK.
Shipping Dumbbells
Shipping heavy items shouldn’t cost you its weight in gold. For tips and tricks on how to make shipping heavy items cheaper, check out our recent blog post here.
Big news: ShipHero is hiring!
We’re looking for exceptional people to join our exceptional team. Like who you work with, enjoy what you do, and find your path to success in the skyrocketing field of ecommerce.
Check out our available roles and apply today!
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Welcome to the monthly ShipHero Fixes & Features email. Our Product Team has been working hard to bring several new and impactful fixes and features to life.
There is a new setting that you can enable – Require an order to be fully picked before shipping.
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When enabled, if an order is not fully picked, a message will be displayed when the tote is scanned and the order will not be able to be shipped.
Have you tried RateShop+ yet? It’s the newest way to get the cheapest rates with the best service level based on your parameters! Plus, we’ve added extra features like weighting different methods and carriers. Do you get cashback on your credit card when you use carriers like USPS, FedEx, or UPS? You can capitalize on this kind of incentive by weighting these carriers, ensuring they are always the cheapest method for specific service levels.
Find out more about RateShop+ in our Knowledge Base. The feature is currently available to all current WMS clients for free!
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