Glass Manufacturer Improved Order Fulfillment Accuracy By 78% With Kure
Project Summary
The problem: Order fulfillment errors were leading to incorrect and incomplete shipments, creating delays for customers and added rework for internal teams.
After implementing improvements in Kure, monthly picking errors dropped from 9 to 2, resulting in a 78% increase in order fulfillment accuracy.
Introduction
Reliable order fulfillment is more than a logistics function—it directly impacts customer satisfaction, operational flow, and overall business performance. When errors occur, they can quickly disrupt production timelines, increase costs, and weaken trust.
To solve this challenge, the organization combined GLSS Training & Certification with Kure, creating a seamless path from learning to execution. Instead of applying improvement concepts in isolation, the team used Kure’s guided workflow to analyze the process, test solutions, and track progress in real time.
Throughout the effort, the team embraced Ethical Efficiency™, focusing on improvements that not only increased accuracy, but also made the process clearer and easier for employees to follow.
The Problem
The distribution team was facing ongoing issues with order accuracy. Customers occasionally received shipments that were missing items or contained the wrong products.
These issues had a direct impact on customers’ operations. In some cases, production had to pause while replacement items were sourced and delivered. Internally, teams spent additional time correcting mistakes, including repicking, repacking, and reshipping orders.
Over time, this rework created unnecessary costs and reduced overall efficiency. Leadership recognized that improving accuracy at the source would eliminate downstream problems and strengthen service reliability.
The Root Causes
Using Kure, the team worked through a structured analysis and uncovered two key gaps in the process.
First, there were no built-in controls to prevent items from being picked from the wrong location. With similar products stored close together, it was easy for employees to unintentionally select the wrong item.
Second, the process relied heavily on memory and attention to detail. While employees were trained on general procedures, there was limited reinforcement around verifying the exact picking location during execution.
By documenting these findings within Kure, the team was able to clearly link process weaknesses to the errors being experienced.
The Solutions
The team focused on simplifying the process and reducing reliance on manual checks.
They introduced a system-based control that restricts picking to the correct storage location for each order. This created a built-in safeguard that guides employees to the right location and prevents incorrect selections.
Kure supported implementation by organizing each step of the improvement, keeping the team aligned, and providing visibility into progress.
With this change, the process became more intuitive and less dependent on individual judgment, reducing the opportunity for mistakes.
The Results
The improvements led to immediate and measurable gains.
Before the changes, the team experienced an average of nine picking errors per month. After implementing the new control, errors decreased to two per month.
This represents a 78% improvement in order fulfillment accuracy.
As a result, the organization reduced rework, lowered labor costs, and improved the consistency of its shipments. Customers now receive accurate orders more reliably, helping them maintain uninterrupted operations.
Conclusion
This project highlights how combining GLSS Training with Kure enables teams to turn insight into action quickly.
Kure’s structured, AI-supported workflow helped the team stay focused, organized, and aligned from start to finish. By guiding each phase of the improvement process, the team was able to identify root causes, implement effective solutions, and achieve measurable results without unnecessary delays.
Grounded in Ethical Efficiency™, the improvements not only increased accuracy, but also created a process that better supports the people doing the work.
With a stronger fulfillment system in place, the organization is now better positioned to scale operations, sustain improvements, and continue driving meaningful results.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
