Reducing Errors in Backorder Management and Partial Shipments
— ERP-Driven Strategies to Keep Inventory Accurate and Customers Confident
📦 Why Backorder and Partial Shipment Errors Are So Costly
In the construction supply world, a single missing load of drywall or an incorrect batch of pavers isn’t just a mistake—it’s a project delay, a cost overrun, and sometimes a lost client.
Backorders and partial shipments are often unavoidable, but errors don’t have to be. The key is building warehouse workflows and ERP systems that prevent confusion and ensure accuracy from pick to delivery.
✅ Step 1: Automate Inventory Checks Before Committing to Orders
The Problem:
Manual inventory checks or outdated stock visibility can lead to unintentional backorders or partials.
ERP Fix:
Enable real-time inventory visibility across all locations
Block overselling by reserving stock during order entry
Notify the sales team immediately if an item is unavailable or low in stock
➡️ Sell with confidence, not crossed fingers.
✅ Step 2: Split Orders Intelligently Based on Availability
The Problem:
Partial shipments often get processed manually, leading to incomplete pick lists or incorrect dispatch.
ERP Fix:
Use auto-split order logic to divide shipments based on what’s in stock
Label orders as “Partial Shipment #1 of 2,” etc.
Generate specific packing lists and shipping docs for each part of the order
➡️ Clarity in picking = accuracy in delivery.
✅ Step 3: Use Barcode Scanning and Verification at Every Stage
The Problem:
Manual picking and loading increase the risk of the wrong SKU or quantity being shipped.
ERP Fix:
Implement barcode or QR scanning at picking and packing
Require a digital double-check before items are marked as shipped
Enable mobile ERP access so teams can scan, verify, and confirm on the go
➡️ No more “Oops, we sent the wrong bundle.”
✅ Step 4: Communicate Clearly with Customers About What’s Shipped
The Problem:
Customers often assume a delivery is complete—even if it’s a partial. Cue the angry phone call. 😬
ERP Fix:
Send automated notifications showing shipped vs. backordered items
Include itemized packing slips with clear backorder status
Offer live tracking and expected arrival dates through the ERP’s customer portal
➡️ Transparency builds trust.
✅ Step 5: Track and Prioritize Open Backorders
The Problem:
Backorders are easy to forget if they’re not actively monitored—leading to delays and double orders.
ERP Fix:
Use backorder dashboards to view open orders by date, customer, and item
Set alerts for incoming stock so backorders are fulfilled first
Prioritize backordered items during receiving with auto-pick suggestions
➡️ Your system remembers so your team doesn’t have to.
✅ Step 6: Minimize Rehandling and Warehouse Congestion
The Problem:
Handling the same item multiple times (first for the partial, then the backorder) increases risk of damage and lost time.
ERP Fix:
Batch backordered items for consolidated picking when stock arrives
Use ERP to plan minimal-move staging areas for pending stock
Reduce unnecessary stock movement with optimized bin locations
➡️ Fewer touches = fewer errors.
✅ Step 7: Track Error Rates and Use Data to Improve
The Problem:
Without tracking what goes wrong, it’s hard to improve.
ERP Fix:
Log mispicks, wrong deliveries, and customer complaints by order type
Track error rate by team or process stage
Run monthly reports to identify recurring weak spots
➡️ Improve one order at a time—with data that actually matters.
