What is a barcode, really?
A barcode is just a printed license plate for things (or places). When you scan it, your system looks up the record tied to that code. There is no typing or guesswork involved.
Product barcodes on retail items (like UPC/EAN) already exist on most products you buy and sell. You can use them to identify the item in your inventory system. GS1
Internal barcodes are ones you print for bins, racks, pallets, and any items that don’t come labeled. Most warehouses use Code 128 for internal labels because it’s compact and scans easily.
For cases and lots (expiry, batch), many companies use GS1-128 barcodes that can include extra data like GTIN (item), lot, and expiration—all in one code. GS1 US DocumentsGS1-128 INFO
Big picture: you don’t have to change how you sell. Barcodes just remove typing and uncertainty inside your four walls.
Why should a small business bother?
1) Fewer mistakes and returns
Scanning beats typing. In healthcare (a high-stakes environment), switching to barcode verification cut medication administration errors ~41% and reduced potential adverse events by ~51%. Warehouses see the same kind of benefit: scans verify “right item, right place, right quantity.” Scholars@Duke
The CDC likewise recommends barcoding as an evidence-based best practice to reduce identification errors. CDC
2) Real dollars back
Industry surveys estimate mispicks can cost ~$22-$30 each and add up to ~$390k per year in a typical warehouse. Even at much smaller scale, eliminating a chunk of mispicks quickly pays for basic scanners and labels.
3) Speed without heroics
Scanning a location and item is faster than typing codes, searching lists, or walking back to check a shelf. EmissaryWMS supports scanning barcodes out of the box
Where to use barcodes in a warehouse
A) Label your locations
Give every slot a clear human-readable name and a barcode that encodes it (e.g., A03-B02-L01). Place labels where a picker can scan without climbing. Long-range or duplicate labels help on tall bays. Hopstack, Camcode
Quick setup:
Define a simple scheme (Zone-Aisle-Bay-Level-Position).
Print durable labels (laminated or metal if needed; use freezer-grade materials in cold rooms). idlabelinc.com
Stick them consistently on rack beams and bin fronts.
B) Use existing UPC/EAN on products
Most consumer goods already carry a UPC/EAN. Map that barcode to your existing SKU once. After that, any scan (at receiving, picking, counting) instantly identifies the item.
C) Track movement between locations
A clean, low-friction workflow is:
Scan the source location
Scan the item SKU or UPC
Enter the quantity to pick and submit. The item will now be on your device, with your device set as the location.
Repeat the steps above using the destination location to deposit the product to.
D) Cycle counting (fast, accurate spot checks)
Scan the location first, then scan each item and enter the quantity. This reduces transcription errors and gives you on-hand accuracy without shutting down.
E) Query any location on the fly
Scan a location and instantly see its contents and quantities. EmissaryWMS allows you to scan a location to view current inventory stored.
What you need to get started
Label printer: prints durable barcodes for locations and internal item tags. There are two types: Direct Thermal and Thermal Transfer. Thermal Transfer will allow labels to last longer but Direct Thermal will suffice.
Labels. Ensure that the label type you use matches the printer type. Use direct thermal labels for direct thermal printers, for example.
Scanners or mobile computers: start with a couple of Bluetooth scanners paired to phones/tablets, or use our camera function in the EmissaryWMS app.
Software: EmissaryWMS is the solution that ties this all together.
FAQ
Do I have to relabel everything I sell?
No. Start by using the labels you already have: UPC/EAN on retail items. Only print internal labels for unlabeled items and all warehouse locations.
Will scanning really reduce errors for a small shop?
Yes. Across industries, replacing manual entry with barcode checks reduces human error dramatically (e.g., 41% fewer administration errors in a rigorous NEJM study). Warehouses benefit in the same way by reducing mispicks and better on-hand accuracy. Scholars@Duke
What’s the ROI?
Even modest reductions in mispicks (often ~$22-$30 each) add up quickly, and many DCs report annual losses near $390k from mispicks. This is scaled down proportionally for smaller operations.
Bottom line
- Start small label your locations, and map UPC/EAN to your SKUs. You’ll see fewer errors, faster tasks, and more accurate inventory without a big, risky project!
- Ask Questions! We are here to help you out! Reach out to us for any questions you have about your set up and configuration.