Analysing role of technology system, storage design and material handling to improve warehouse operation accuracy

Warehouse operation inaccuracy remains a critical issue in manufacturing companies, often resulting in operational inefficiencies, production delays, and increased costs. This research analyses the extent to which technology system, storage design, and material handling influences inventory accuracy in manufacturing warehouses, with a specific focus on facilities located in Kulim Hi-Tech Park, Malaysia. This research contributes positively to the manufacturing industry by significantly improve inventory accuracy. Enhanced accuracy leads to greater operational efficiency, cost savings, and more informed decision-making. The findings also support Industry 4.0 adoption by demonstrating the value of digital systems like RFID and WMS. Furthermore, the study provides practical insights for benchmarking, policy development, and workforce training, ultimately helping manufacturers optimize their warehouse operations and remain competitive. A total of 40 manufacturing companies operating within Kulim Hi-Tech Park were identified as the sampling frame for this study. Based on the Krejcie and Morgan (1970) table, the planned sample size was determined to be 36 respondents, representing personnel involved in warehouse and inventory operations across these companies. A quantitative research approach was employed, utilizing structured questionnaires distributed to supply chain professionals and warehouse personnel within selected manufacturing companies. The study applied descriptive statistics to evaluate relationships among key variables. The findings reveal that the implementation of system applications such as RFID, barcode systems, and WMS significantly enhances inventory visibility and tracking. Additionally, optimized storage design characterized by layout planning, slotting strategies, and accessibility contributes positively to inventory accuracy. Furthermore, effective material handling, including automation, and standardized operating procedures, are also associated with reduced inventory errors. The implications extend to industry practitioners aiming to improve operational efficiency and to policymakers advocating for Industry 4.0 readiness in manufacturing logistics. Future research should explore longitudinal data and include qualitative insights to enrich the understanding of human and organizational factors.