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Key Responsibilities and Required Skills for Warehouse Material Handler

💰 $28,000 - $48,000 / year

LogisticsWarehouseOperationsManufacturingSupply Chain

🎯 Role Definition

A Warehouse Material Handler is responsible for the safe, accurate, and efficient movement, storage, staging, and processing of materials and finished goods within a warehouse or distribution environment. This role focuses on shipping and receiving tasks, inventory control, proper equipment operation (forklift, pallet jack, RF scanners), and adherence to safety and quality standards. The ideal candidate combines physical stamina with attention to detail and strong teamwork skills to support daily operations and continuous improvement initiatives.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Seasonal Warehouse Associate or Picker/Packer
  • Receiving Clerk or Shipping Assistant
  • Manufacturing Line Associate or General Labor

Advancement To:

  • Lead Material Handler / Lead Warehouse Associate
  • Shipping & Receiving Supervisor
  • Inventory Control Specialist
  • Warehouse Supervisor / Operations Coordinator

Lateral Moves:

  • Forklift Operator (certified)
  • Quality Control Inspector
  • Logistics Coordinator

Core Responsibilities

Primary Functions

  • Receive inbound shipments, inspect packages for damage, verify counts and part numbers against purchase orders and packing lists, and accurately record receipt information in the warehouse management system (WMS).
  • Unload trucks and containers using appropriate equipment (sit-down and stand-up forklifts, reach trucks, pallet jacks), ensuring safe handling of fragile, oversized, or hazardous goods and maintaining load integrity.
  • Stage and organize inbound material by SKU, product family, and storage location using cycle-counted locations and proper pallet configuration to maximize space utilization and accessibility.
  • Pick and pack orders according to pick tickets and customer specifications, ensuring accuracy of item, quantity, and packaging to meet shipping deadlines and reduce returns.
  • Operate RF/mobile scanning devices to complete picks, updates, and inventory transactions in real time; troubleshoot scan errors and coordinate fixes with inventory control.
  • Perform daily forklift pre-shift inspections, report maintenance issues, and follow lockout/tagout and other safety protocols to ensure equipment readiness and regulatory compliance.
  • Load outbound shipments according to carrier and load plan requirements, secure freight with straps/brace/edge protection, and verify shipping paperwork including bills of lading, manifests, and carrier labels.
  • Conduct regular cycle counts and physical inventory audits, investigate discrepancies, update records, and collaborate with inventory control to implement root-cause corrective actions.
  • Label and barcode all incoming and stored materials accurately; create and apply lot numbers, expiry dates, and serial numbers as required for traceability and compliance.
  • Maintain clean, organized aisles, staging areas, and pallet positions; remove debris and implement 5S/lean principles to improve safety and throughput.
  • Handle returns (RMA) processing: inspect returned goods, document condition, restock sellable items, and prepare non-conforming items for disposition.
  • Verify and process shipping documentation for LTL and TL carriers, coordinate pickups, and prepare export/import paperwork when required, ensuring correct incoterms and customs compliance.
  • Follow hazardous materials handling guidelines (OSHA, DOT, WHMIS) when storing, moving, or disposing of regulated items; maintain and reference MSDS/SDS documentation.
  • Coordinate with production, procurement, and quality teams to prioritize urgent parts, expedite orders, and stage kitted components for assembly lines or customer shipments.
  • Support cross-docking activities: break down full pallets into individual orders, consolidate shipments, and minimize double-handling to improve transit times.
  • Execute end-of-day manifests and reconcile shipment counts against WMS, escalate variances to supervisors, and prepare exception reports for corrective actions.
  • Train and mentor junior material handlers in safe lifting techniques, equipment operation, picking strategies, and company-specific procedures to ensure team competency.
  • Use basic computer skills to enter data, create shipping labels, run inventory reports, and communicate with internal systems (ERP/WMS such as SAP, Oracle, Manhattan, or Fishbowl).
  • Maintain accurate staging for outbound docks, verifying load sequences to support dock scheduling and carrier on-time performance.
  • Participate in continuous improvement projects, suggesting workflow optimizations, layout adjustments, and process standardization to increase productivity and reduce errors.
  • Ensure all quality checks and inspection points are completed for critical SKUs, documenting non-conformances and initiating hold procedures when necessary.
  • Support emergency response and incident reporting when safety events occur, participating in investigations and implementing preventive actions.

Secondary Functions

  • Assist in light maintenance of material handling equipment and report safety hazards or operational inefficiencies to the supervisor.
  • Support replenishment activities by moving stock from bulk storage to pick faces based on min/max levels and demand forecasts.
  • Help prepare pick lists, packing materials, and shipping pallets for seasonal surges, promotions, or large orders that require special handling.
  • Coordinate with third-party logistics (3PL) partners and carrier representatives for inbound/outbound scheduling, claims resolution, and service-level compliance.
  • Participate in onboarding and cross-training programs to maintain flexible staffing across shifts and support continuity during absences or peaks.
  • Compile daily activity logs, safety checklists, and productivity metrics to inform supervisors and drive departmental KPIs.

Required Skills & Competencies

Hard Skills (Technical)

  • Forklift operation (counterbalance, reach, pallet jack) with valid certification and demonstrated safe operation experience.
  • Proficient use of RF barcode scanners and mobile data terminals for picking, receiving, and cycle counting.
  • Experience with Warehouse Management Systems (WMS) and common ERPs such as SAP, Oracle, Manhattan, Infor, or Fishbowl.
  • Strong knowledge of shipping and receiving processes including BOL creation, carrier paperwork, freight labeling, and LTL/TL procedures.
  • Inventory control and cycle-count methodology, including root-cause analysis for discrepancies and adjustments.
  • Familiarity with hazardous materials handling and regulatory compliance (OSHA, DOT, MSDS/SDS).
  • Ability to read and interpret packing lists, purchase orders, shipping manifests, and SKU labels.
  • Palletizing and load securement techniques (strapping, stretch-wrap, edge protection) and load sequencing for safe transport.
  • Basic computer literacy: email, Excel, scanning software, and entry of transactions into WMS/ERP.
  • Experience with pick/pack/packaging workflows, kitting, and assembly staging.
  • Physical ability to lift, push, pull, and carry up to company-standard weight limits repeatedly throughout the shift.

Soft Skills

  • Strong attention to detail and accuracy to minimize shipping errors and inventory variances.
  • Time management and ability to prioritize tasks in a fast-paced distribution environment.
  • Clear verbal communication and teamwork with warehouse staff, supervisors, and cross-functional partners.
  • Problem-solving mindset to identify bottlenecks and suggest process improvements.
  • Reliability and punctuality; ability to work scheduled shifts and overtime during peak periods.
  • Safety-first attitude with willingness to follow procedures and promote a safe workplace.
  • Adaptability to changing priorities, new systems, and seasonal demand fluctuations.
  • Customer-focused orientation for internal and external stakeholders.
  • Initiative to proactively report issues and recommend corrective action.
  • Patience and resilience when managing repetitive tasks or high-volume shipping windows.

Education & Experience

Educational Background

Minimum Education:

  • High School Diploma or GED (or equivalent work experience in warehouse/production environments).

Preferred Education:

  • Vocational training or certificate in logistics, material handling, or warehouse operations.
  • Forklift certification or safety training credentials.

Relevant Fields of Study:

  • Logistics & Supply Chain Management
  • Operations Management
  • Industrial Technology
  • Business Administration (with logistics coursework)

Experience Requirements

Typical Experience Range:

  • 0–5 years in warehouse, distribution center, manufacturing, or logistics roles.

Preferred:

  • 1–3 years of direct material handling, shipping/receiving, or inventory control experience in a fast-paced warehouse environment.
  • Proven experience operating forklifts and RF scanning systems; demonstrated familiarity with WMS/ERP systems.
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