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Key Responsibilities and Required Skills for Warehouse Process Technician

💰 $40,000 - $65,000

OperationsLogisticsWarehouse

🎯 Role Definition

A Warehouse Process Technician is responsible for maintaining and improving warehouse operations by executing and optimizing material flow processes, ensuring inventory accuracy, supporting equipment and automation, and enforcing safety and quality standards. This hands-on role blends operational execution (picking, packing, receiving) with process optimization (SOP adherence, Kaizen activities, root-cause problem solving) and data-driven reporting to improve throughput, accuracy, and cost efficiency within a distribution or manufacturing warehouse environment.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Warehouse Associate / Material Handler
  • Shipping & Receiving Clerk
  • Production Operator

Advancement To:

  • Senior Warehouse Process Technician / Process Lead
  • Warehouse Supervisor / Shift Lead
  • Continuous Improvement Specialist / Lean Engineer
  • Maintenance Technician or Reliability Engineer

Lateral Moves:

  • Inventory Control Analyst
  • Quality Inspector / QA Technician
  • Systems / WMS Analyst

Core Responsibilities

Primary Functions

  • Execute and optimize daily warehouse workflows including receiving, put-away, picking, packing, staging, and shipping while meeting productivity and accuracy KPIs such as picks per hour, on-time shipments, and order accuracy.
  • Operate powered industrial trucks (forklifts, reach trucks, pallet jacks) and material handling equipment safely and efficiently in accordance with OSHA and internal safety protocols.
  • Perform cycle counts, bin-to-bin transfers, and full inventory audits; investigate discrepancies, reconcile physical inventory to WMS records, and prepare variance reports for management review.
  • Identify and document process deviations and nonconformances; lead root cause analysis (5 Whys, Ishikawa) and implement corrective actions to reduce repeat issues and improve first-time quality.
  • Troubleshoot conveyor, sorter and automated storage/retrieval systems (AS/RS) to identify mechanical or operational causes of downtime and coordinate with maintenance or engineering for repairs and preventive maintenance.
  • Maintain and update standard operating procedures (SOPs), work instructions, and visual aids; ensure frontline teams have current documentation and understand process expectations.
  • Support onboarding and training of new hires and cross-functional personnel on process steps, safety procedures, and equipment operation; run practical training sessions and competency checks.
  • Execute order consolidation, staging and loading plans for mixed pallets, multi-stop shipments, and LTL/FCL loads to maximize cube utilization and minimize damage in transit.
  • Monitor and adjust slotting strategies and pick-paths to improve picking efficiency and reduce travel time; recommend re-slotting based on velocity, case pack, and product dimensions.
  • Use Warehouse Management Systems (WMS) and RF handhelds to confirm receipts, put-away locations, picks, and shipments; escalate WMS issues and maintain data integrity.
  • Prepare and verify shipping documentation including bills of lading, packing lists, labels, and hazardous materials paperwork ensuring compliance with carrier and regulatory requirements.
  • Participate in continuous improvement and Kaizen events to streamline processes, implement 5S, reduce waste (muda), and drive measurable productivity gains.
  • Monitor key performance indicators (KPIs) such as inventory accuracy, order cycle time, dock-to-stock time, and on-time delivery; generate daily/weekly reports and suggest corrective actions.
  • Lead or support quality inspection activities for incoming materials and outbound shipments, documenting non-conformances and coordinating returns, rework, or disposition.
  • Support receiving inspections: verify quantities, count and record lot numbers/serial numbers, inspect packaging for damage, and initiate claims with carriers when required.
  • Conduct preventive maintenance checks and basic mechanical adjustments on conveyors, palletizers, stretch wrappers, and labelers; collaborate with maintenance for planned downtime and repairs.
  • Coordinate with procurement, planning, and production to prioritize replenishment activity, expedite critical SKUs, and maintain minimum and safety stock levels.
  • Execute hazardous material (HAZMAT) handling and storage tasks in compliance with DOT, OSHA, and company policies when applicable, including correct segregation and labeling.
  • Implement and enforce material traceability protocols (lot control, expiration dates, serial tracking) for regulated products or high-value inventory.
  • Support seasonal or peak operational plans by adjusting labor allocation, process flows, and temporary slotting to maintain service levels during high-volume periods.
  • Investigate and report near-misses, safety incidents and process failures; develop mitigation plans and communicate lessons learned across teams to prevent recurrence.
  • Collaborate with IT and WMS teams to test and validate system changes, software updates, or integrations that affect warehouse processes and transaction flows.

Secondary Functions

  • Maintain detailed process documentation, change logs, and transaction records to support audits (internal, ISO, GMP) and regulatory compliance reviews.
  • Assist supply chain and operations leaders with ad-hoc data pulls, KPI dashboards, and root-cause data analyses using Excel, pivot tables, and WMS reporting tools.
  • Serve as a cross-functional liaison with maintenance, quality, planning and logistics to coordinate process improvements and scope-of-work for engineering projects.
  • Participate in pilot tests for new equipment, automation, or software; provide feedback, create standard work, and train operators after deployment.
  • Support customer returns processing and disposition workflows, ensuring accurate credit, restocking, or disposal actions following return policies.
  • Aid in continuous improvement initiatives such as 5S audits, ergonomics assessments, and waste reduction projects that improve safety and throughput.
  • Prepare and present process change proposals, business case analyses, and impact assessments to operations management and supply chain stakeholders.
  • Maintain spare parts lists, tools, and consumables for critical equipment to reduce mean time to repair (MTTR) and maintain uptime.
  • Support vendor onboarding and field service coordination for third-party equipment maintenance or calibration needs.
  • Participate in emergency response and business continuity activities, including cross-training for critical functions to ensure minimal disruption during staffing shortages or incidents.

Required Skills & Competencies

Hard Skills (Technical)

  • Proficient with Warehouse Management Systems (WMS) such as SAP EWM, Oracle WMS, Manhattan, or equivalent, including RF handheld transactions and cycle count workflows.
  • Experienced operating powered industrial trucks: sit-down forklifts, reach trucks, stand-up forklifts, order pickers and pallet jacks; valid certifications preferred.
  • Strong inventory control and physical counting skills (cycle counts, blind counts, reconciliation) with a demonstrated history of improving inventory accuracy.
  • Knowledge of shipping/receiving processes, BOL preparation, carrier routing, LTL and FTL coordination, and palletization best practices.
  • Familiarity with conveyor systems, sortation equipment, automated storage and retrieval systems (AS/RS), and basic troubleshooting methods.
  • Competence in reading and updating SOPs, work instructions, and using visual management tools (Kanban, floor markings).
  • Basic mechanical aptitude for equipment adjustments and preventive maintenance; ability to read simple mechanical drawings and manuals.
  • Working knowledge of safety regulations (OSHA), material handling compliance, hazardous materials handling (DOT/49 CFR) where applicable.
  • Proficient in Microsoft Excel (VLOOKUP, pivot tables) and comfortable creating daily/weekly operational reports from WMS data.
  • Experience with continuous improvement tools: Lean, 5S, Kaizen, Value Stream Mapping, and root cause analysis (5 Whys, fishbone diagrams).
  • Basic understanding of ERP integration points, lot/serial traceability, and lot control processes for regulated industries.

Soft Skills

  • Strong attention to detail and methodical approach to inventory accuracy and process compliance.
  • Excellent problem-solving and analytical skills with the ability to translate data into actionable process improvements.
  • Effective verbal and written communication skills to document issues, create SOPs, and train peers and stakeholders.
  • Team player who collaborates cross-functionally and works effectively under pressure in a fast-paced warehouse environment.
  • Time management and prioritization skills to balance daily operational tasks with improvement projects and audits.
  • Safety-first mindset with the ability to coach others and enforce safe behaviors.
  • Adaptability and willingness to learn new technologies, systems, and equipment quickly.
  • Leadership potential and initiative to lead small teams or projects even without formal supervisory responsibility.
  • Customer-focused orientation with an understanding of how warehouse processes impact end-to-end supply chain performance.
  • Strong organizational skills and the ability to maintain clean, compliant, and efficient work areas.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED required.

Preferred Education:

  • Associate degree or technical certificate in Logistics, Supply Chain, Industrial Technology, or related field.

Relevant Fields of Study:

  • Supply Chain Management / Logistics
  • Industrial Engineering / Manufacturing Technology
  • Operations Management
  • Mechanical or Electrical Technology

Experience Requirements

Typical Experience Range:

  • 1–5 years of hands-on warehouse or distribution center experience, with at least 1 year in a role involving process ownership, inventory control, or equipment operation.

Preferred:

  • 2–4 years as a Process Technician, Inventory Control Specialist, or equivalent with demonstrable improvement projects (Lean/Kaizen) and WMS experience.
  • Experience in regulated environments (GMP, ISO) or with high-mix/low-volume operations is a plus.
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