Mccollisters Global Services Reduces Labeling Errors Saves Costs

Published: 01/28/2026
Label Optimization Lean Logistics Cost Control
McCollister's implemented lean improvements to optimize label design and barcode scanning processes. This label optimization initiative significantly increased label accuracy from less than 90% to 99.8%. By streamlining their logistics through lean principles, they achieved substantial cost reductions and improved overall efficiency. The enhanced accuracy and efficiency also contributed to increased customer satisfaction. The focus on lean logistics and meticulous label optimization proved to be a successful strategy for achieving cost control and operational excellence.
Mccollisters Global Services Reduces Labeling Errors Saves Costs

Imagine facing up to 20 labeling errors daily, each potentially costing $1,000. For logistics companies, this isn't just a financial burden—it threatens operational efficiency, customer satisfaction, and corporate reputation. McCollister's Global Services confronted this challenge head-on and implemented a remarkably effective solution, boosting their label accuracy to an impressive 99.8%.

Specializing in specialized transportation and warehousing services, McCollister's undertook a comprehensive evaluation of their labeling process as part of lean process improvements. The findings revealed significant operational flaws causing frequent labeling mistakes that led to material losses and eroded customer trust through delayed order processing.

Root Causes: Why Labels Went Wrong

McCollister's warehouse solutions team identified several critical issues:

  • Human limitations: Manual labeling proved vulnerable to operator fatigue and attention lapses
  • Information discrepancies: Data corruption occurred during interdepartmental transfers
  • Design flaws: Poorly structured labels caused misinterpretation
  • Quality gaps: No robust system existed to catch errors early

The Turnaround: Strategic Process Improvements

McCollister's implemented targeted corrective measures:

  • Label redesign: Enhanced clarity through larger fonts, high-contrast colors, and simplified layouts
  • Barcode integration: Automated data capture replaced error-prone manual entry
  • Standardization: Uniform procedures with comprehensive staff training
  • Quality controls: Multi-stage verification checks at critical points
  • Ergonomic upgrades: Improved workstations reduced physical strain and fatigue

Transformational Results

The interventions yielded dramatic improvements:

  • Label accuracy surged from below 90% to 99.8%
  • Employee satisfaction increased through reduced rework
  • Operational costs dropped significantly
  • Customer relationships strengthened through reliable deliveries

Tyler Yoos, Vice President and General Manager at McCollister's, emphasized how cost-effective solutions dramatically enhanced their labeling operations while improving employee morale. The case demonstrates how meticulous attention to seemingly minor processes can yield substantial business advantages.

Industry Takeaways

McCollister's experience offers valuable lessons for logistics operators:

  • Scrutinize all processes, regardless of perceived significance
  • Pursue continuous incremental improvements
  • Prioritize workforce conditions and satisfaction
  • Leverage data analytics for problem identification and solution validation

This approach enables logistics providers to minimize labeling errors, enhance operational efficiency, and strengthen competitive positioning—all through methodical process optimization.

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