Snuck into the warehouse at 5am and found the shipping crew's secret shortcut
Worked at a small furniture place in Fort Worth for two years. Our order pick times were always behind and the boss kept blaming the software. One morning I came in early and saw the night crew pulling orders from memory, not the system. They had been writing aisle numbers on the backs of their hands and skipping two whole sections because the scanner route was wrong. I copied their little cheat sheet and my pick time went from 22 minutes down to 9. Told the manager and he just stared at it. Anyone else ever find out the floor knew more than the system did?
Sounds like a routing problem more than a secret, the system just had bad aisle data. Not really shocking that the guys doing it every night know the fastest path better than some software nobody updated.