A3 Problem Report — Repeat mispicks on the aisle 7 fast-mover bins during the night shift. Three in four weeks, all found at dispatch.

Background / Problem

Repeat mispicks on the aisle 7 fast-mover bins during the night shift. Three in four weeks, all found at dispatch.

Root-cause analysis

Two look-alike SKUs are slotted side by side in the aisle 7 fast-mover bins. [Layout & Slotting] ✓ verified

Evidence: Walked the bay with the night shift lead: the two SKUs sit in adjacent bins with near-identical cartons. All three mispicks swapped this pair. (by shift.lead@example.com, 12 June 2026)

↳ Slotting was set by velocity alone, with no check for similar packaging. [Process] ✓ verified

Evidence: Slotting rules export shows velocity as the only input; no packaging attribute is checked. (by ci.lead@example.com, 12 June 2026)

The scan step accepts the bin without asking the picker to confirm it. [WMS/System] ✓ verified

Evidence: Repeated the pick on the test handset: the scan accepted the neighbouring bin with no prompt. (by wms.lead@example.com, 13 June 2026)

First answer given: the picker was not paying attention. Ruled out: the same picker made no errors on other aisles, and the night shift's mispicks were all on this bay. [People] not verified: raised, no evidence recorded

✓ verified: confirmed against evidence. Causes marked "not verified" were raised during the investigation and not supported; they are kept so the reasoning is visible.

Countermeasures and follow-up

Countermeasure	Owner	Due	Effectiveness check	Did it hold?
Reslot the aisle 7 fast movers so the look-alike pair is separated by at least one bay.	Night Shift Manager	19 June 2026	17 July 2026	Held: verdict recorded 17 July 2026 by night.manager@example.com
Add a scan-to-confirm prompt on the flagged look-alike SKUs and add packaging similarity to the slotting check.	WMS Lead	26 June 2026	24 July 2026	Held: verdict recorded 24 July 2026 by wms.lead@example.com

Sign-off

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