Misshipments Guide: Why They Happen and How to Prevent Them

Ever opened a package and thought, This isn’t what I ordered…? Or tracked your shipment, only to see it was delivered to someone else?

These mix-ups frustrate customers and drain time and money.

Misshipments don’t just happen—they often signal deeper issues in your process. In this guide, you’ll see why they occur and how to keep them from slowing your business down...

What is a Misshipment?

A misshipment is any mistake that happens when shipping an order, causing the package to arrive incorrectly or not as the customer expected.

It can happen for many reasons, including picking and packing errors, labeling mix-ups, or gaps in communication with carriers.

No matter the cause, they disrupt fulfillment operations and can quickly impact customer satisfaction and your bottom line.

How Does Misshipment Affect Businesses?

Misshipments don’t just frustrate customers. They also create real problems for your operations, costs, and long-term growth.

Here are the top ways they hurt businesses:

Increased Operational Costs

Every misshipment creates extra work and expense.

Reports show that 83% of customers expect free returns for shipping mistakes, costing businesses an extra $10–$50 per order plus the time and labor to resolve each issue.

Damaged Brand Reputation

Customers today expect fast, accurate deliveries.

Research shows that one in three customers will leave a brand after just one bad experience, and nearly 60% will share complaints, leading to fewer new customers and a damaged reputation that’s hard to fix.

Lower Operational Efficiency

Misshipments create ripple effects across your entire fulfillment operation. Time spent tracking down incorrect shipments, processing returns, updating inventory records, and responding to customer complaints all adds up.

Over time, this can strain your team and lead to more frequent mistakes.

Why Do Misshipments Happen?

Misshipments can happen in different ways. Here are the main types, with examples to show how they usually occur in real operations:

Quantity Error

When the number of items shipped doesn’t match what the customer ordered.

Example

A forklift driver was loading two shipments that each needed a different pallet.

In the rush, the driver mistakenly loaded two of the same pallet instead of one of each. Because no one caught the error during the final check, the truck left with a duplicate shipment.

The intended order was delayed, and extra time was needed to correct the mistake.

Wrong Item

Shipping a completely different product than the one requested.

Example

During a busy shift, a picker hurried to meet performance targets and grabbed an item that looked similar to what was on the pick list.

The barcode scan didn’t catch the error because it matched the general product category.

The wrong product made it all the way to the customer, who received a substitution they hadn’t ordered.

Mislabeled Box

A correct item is packed but has the wrong label applied, causing it to ship to the wrong address.

Example

A packer placed a label intended for another order on a customer’s box.

Even though the barcode was technically valid, it belonged to a different shipment.

The order was delivered to the wrong address, and the intended customer had to wait longer for a replacement.

Package Delivered to the Wrong Customer

A shipment arrives at an unintended recipient’s address.

Example

An address was entered incorrectly during order creation, and no verification step caught it.

The order was dispatched and delivered to a customer with a similar name in a different state.

The actual buyer only found out when they checked tracking and saw the delivery confirmation to the wrong location.

Package Sent to the Wrong Sorting Facility

A shipment is routed to the wrong distribution center or postal office during transit.

Example

A package meant to go to Springfield, Illinois, was mislabeled at the warehouse and instead sent to Springfield, Oregon.

The carrier needed additional time to reroute the shipment, causing a delay of several days.

Partial Shipment

Only part of an order is shipped, leaving out one or more items.

Example

A customer ordered three items, but only two were packed and sent.

Because inventory records were inaccurate, the picker thought the third item was out of stock and closed the order prematurely.

The customer received an incomplete shipment and had to open a support case to get the missing item fulfilled.

Lack of Shipping Visibility

Errors go unnoticed in transit because there’s no real-time tracking or exception alerts.

Example

A customer purchased a laptop. The wrong model was picked, and by the time the mistake was reported, the package was already en route.

Since there was no tracking visibility, the carrier needed three extra days to locate and redirect the shipment, frustrating the customer and delaying resolution.

These examples show just how many ways misshipments can occur, often compounding if multiple errors happen in the same order.

How to Prevent Misshipment or At Least Avoid It

Misshipments can be costly and frustrating, but they’re not inevitable. With the right strategies and tools in place, you can catch errors early or prevent them altogether.

Here are some effective ways to reduce misshipments in your operation:

Perform Regular Inventory Checks

Keep your inventory accurate by scheduling frequent cycle counts and audits.

When stock records match what’s actually on the shelves, pickers are less likely to grab the wrong items or over-ship quantities.

Clear, up-to-date inventory data is the foundation of error-free fulfillment.

Use Barcode Scanners

Barcode scanning adds a layer of verification at every stage.

It helps confirm that the correct items are picked, packed properly, and labeled accurately before the order leaves the warehouse.

This is one of the simplest ways to catch mistakes early and prevent shipping errors.

Invest in Robust Order Management Software

A reliable order management system (OMS) or warehouse management system (WMS) can automatically track orders, assign picking tasks, validate SKUs, and generate accurate labels.

This reduces manual handling and lowers the risk of human error.

Set Up a Quality Control Process

Add a dedicated quality check before orders are sealed and shipped.

This could include a second scan of the items against the order, visual confirmation by a team member, or even spot checks of high-value or complex orders.

Maintain Clear Communication with Carriers

Stay in touch with your shipping partners to ensure accurate hand-offs and routing.

Good communication helps prevent packages from being sent to the wrong hub or delivery area, especially during busy periods when volumes spike.

Create a Seamless Returns Process

Even with the best systems, occasional mistakes happen.

Make sure you have a smooth returns workflow so customers can easily send back incorrect items and get replacements quickly.

Clear return instructions and prepaid labels can turn a negative experience into a positive one.

Work with a Reliable 3PL

If you outsource fulfillment, partner with a third-party logistics (3PL) provider known for strict accuracy standards and strong technology integrations.

A quality 3PL can handle inventory, picking, packing, and shipping with systems designed to minimize errors.

How Carriyo Can Help You With Your Misshipment Dilemma

If you’re experiencing misshipments or worried about orders arriving late, incomplete, or at the wrong address, Carriyo can help you get control and build a more reliable shipping operation.

Why? Well, here’s what you can expect:

• Fewer Errors in Every Order: Automate your shipping process so orders are picked, packed, and labeled accurately the first time.
• Faster Problem Resolution: Get instant alerts when something goes wrong, so you can fix issues before customers even notice.
• Complete Visibility Over Shipments: See exactly where every package is in real time, reducing uncertainty and delays.
• Happier, Informed Customers: Keep buyers updated automatically so they feel confident their order is on the way or being corrected.
• Simpler Returns and Replacements: Make it easy for customers to send back the wrong items and quickly get the right ones without hassle.

With Carriyo, you can spend less time reacting to problems and more time delivering a smooth, dependable experience your customers trust.

Final Thoughts

If you’d like to learn more about improving your shipping operations, you can always explore Carriyo or browse our blog for more insights and practical tips.

And if you’re ready to see how we can help you simplify fulfillment and reduce errors, feel free to get in touch with us. We’re here to help you build a shipping experience your customers can rely on.

FAQs

Are misshipments more common during peak seasons?

Yes, high order volumes and temporary staff during holidays often lead to more shipping mistakes.

What should I do immediately after discovering a misshipment?

Confirm the error, notify your customer, and quickly arrange a reshipment or return to resolve the issue.

How do misshipments affect inventory management?

They create stock discrepancies that lead to out-of-sync records, over-ordering, and further fulfillment problems.

Is it possible to fully eliminate misshipments?

You can’t remove them completely, but automation, quality checks, and training can reduce them to very low levels.

What role do carriers play in misshipments?

Carriers handle final delivery, and routing mistakes or damaged labels can cause packages to end up in the wrong place.