Key Responsibilities and Required Skills for Warehouse Process Coordinator

🎯 Role Definition

The Warehouse Process Coordinator is a hands-on operations specialist responsible for designing, documenting, implementing and continuously improving warehouse workflows and standard operating procedures (SOPs). This role works cross-functionally with operations, quality, safety, IT/WMS and supply chain teams to optimize throughput, accuracy and labor productivity while ensuring compliance with safety, regulatory and customer-specific requirements. The Coordinator translates data and KPI trends into actionable process changes, leads small improvement projects (Kaizen/Lean), and serves as the go-to subject matter expert for operational best practices on the warehouse floor.

Keywords: warehouse process coordinator, warehouse operations coordinator, inventory control, process optimization, WMS, SOP development, continuous improvement, logistics.

📈 Career Progression

Typical Career Path

Entry Point From:

Warehouse Associate (picks/packing/shipping) with demonstrated process awareness
Inventory Control Specialist or Cycle Count Coordinator
Logistics Coordinator or Shipping/Receiving Lead

Advancement To:

Warehouse Supervisor / Team Lead
Warehouse Manager / Operations Manager
Process Improvement Manager / Continuous Improvement Lead
Supply Chain Analyst or Distribution Center Manager

Lateral Moves:

Quality / Compliance Coordinator
Safety Coordinator
Inventory Planner / Demand Planner

Core Responsibilities

Primary Functions

Develop, document, and maintain detailed Standard Operating Procedures (SOPs) for receiving, put-away, picking, packing, shipping, returns, and cycle count processes — ensuring clarity, version control, and easy adoption by frontline teams.
Lead cross-functional process improvement projects using Lean, Kaizen or Six Sigma principles to reduce order cycle time, increase picking accuracy and improve labor productivity, delivering measurable KPIs and savings.
Monitor daily warehouse performance metrics (OTD, order accuracy, lines per hour, fill rate, inventory accuracy) and produce clear dashboards and executive summaries that identify trends, root causes and prioritized actions.
Design and implement test plans for process changes (layout changes, slotting, pick path updates, new packing standards), run pilot programs, collect performance data, and scale successful improvements across sites.
Own and optimize workflow and material flow layout in the DC to minimize travel time, reduce touchpoints and improve throughput while ensuring compliance with safety and regulatory constraints.
Coordinate and execute cycle counts and inventory reconciliation processes; investigate discrepancies, conduct root cause analysis, and implement corrective actions to sustain inventory accuracy goals.
Train, coach and certify front-line associates and temporary staff on new SOPs, material handling equipment, RF scanning procedures and quality inspection criteria to ensure consistent execution.
Serve as the primary subject matter expert for Warehouse Management System (WMS) configurations related to wave planning, slotting, replenishment, put-away logic and pick strategies; partner with IT for system releases and troubleshooting.
Drive slotting and replenishment strategies by analyzing demand patterns, velocity, cube and weight to optimize SKU placement and reduce travel and picking time.
Facilitate daily/weekly operational huddles and cross-functional meetings to communicate priorities, share performance results and align on corrective actions and improvement initiatives.
Create and maintain operational documentation including process maps, RACI matrices, work instructions, training curricula and audit checklists to support consistent execution and compliance.
Manage change control for process updates; communicate changes, update training and verify adherence through audits and observations.
Conduct regular process audits and Gemba walks to verify SOP adherence, identify safety or compliance gaps, and drive continuous improvement through corrective action plans.
Lead investigations and root cause analyses for repeat errors, shipping exceptions, damaged goods and logistic disruptions; implement systemic fixes and monitor effectiveness.
Coordinate with maintenance and facilities to schedule preventive maintenance and quick response repairs for material handling equipment (conveyors, forklifts, sorters) to minimize downtime.
Partner with supply planning, transportation and procurement teams to resolve inbound and outbound disruptions, optimize receiving schedules and reduce dock congestion.
Manage returns processing and reverse logistics flows, evaluate return reasons, and recommend process or product changes to reduce return rates and associated costs.
Support vendor and carrier onboarding for new processes (kitting, cross-dock, special packaging), including audits, SOP alignment and SLA definition.
Create job aids, e-learning modules and hands-on training sessions to accelerate new hire ramp-up and cross-train staff across multiple warehouse functions.
Implement and sustain 5S, visual management and quality checkpoints on the warehouse floor to reduce waste, improve safety and create standardized work areas.
Prepare and present weekly/monthly performance reviews for regional operations leadership, highlighting trends, risk areas, and recommended investments or staffing adjustments.
Support audit readiness for customer, regulatory and internal audits by maintaining accurate records, demonstrating control activities and driving remediation plans where required.
Evaluate and recommend automation, handheld scanning, voice picking or software tools based on ROI analysis and scalability to improve accuracy and throughput.
Manage operational escalations from customer service or sales regarding fulfillment exceptions, expedite requests and special handling, ensuring timely resolution and customer communication.

Secondary Functions

Produce ad-hoc analytical reports and data extracts to support route cause analysis and senior leadership decision-making.
Contribute to the organization’s warehouse process roadmap and help prioritize improvements based on cost-to-benefit and customer impact.
Collaborate with cross-functional teams (IT, Quality, Safety, Transportation, Procurement) to translate operational needs into technical requirements and WMS configuration changes.
Participate actively in sprint planning, process workshops and continuous improvement events (Kaizen blitzes, 5S rollouts) to maintain momentum of transformation efforts.
Assist in developing business cases and total cost of ownership (TCO) analyses for proposed equipment or technology investments.
Support temporary labor forecasting and seasonal workforce planning by providing historical productivity and throughput analyses.
Maintain compliance with OSHA, DOT and company-specific safety and security programs; escalate concerns and own mitigation steps.
Help create and maintain KPI definitions, thresholds and escalation matrices that are used across the distribution network.

Required Skills & Competencies

Hard Skills (Technical)

Proven experience with Warehouse Management Systems (WMS) such as Blue Yonder (JDA), Manhattan, SAP EWM, Oracle or equivalent.
Advanced Microsoft Excel skills (pivot tables, VLOOKUP/XLOOKUP, Power Query, basic macros) for reporting and data analysis.
Basic SQL or ability to work with data extracts (CSV/SQL queries) to generate operational metrics and ad-hoc reports.
Strong process mapping and documentation skills using Visio, Lucidchart, or similar tools.
Practical knowledge of Lean methodology, Kaizen events, 5S and continuous improvement tools; Six Sigma Yellow/Green Belt preferred.
Inventory management and cycle count methodology expertise, including reconciliation and root cause analysis.
Experience with slotting optimization tools and SKU profiling (velocity, cube, weight).
Familiarity with RF scanning, barcode systems, conveyor and sorter operations.
Ability to interpret KPIs (OTD, accuracy, productivity, dwell time) and translate into corrective action plans.
Project management skills: planning, scoping, stakeholder management and delivery of process improvement initiatives.
Experience supporting WMS implementations, upgrades or system integrations (ERP/WMS/3PL).
Knowledge of safety and regulatory requirements for warehousing (OSHA, DOT, hazardous materials basics).
Familiarity with voice picking, pick-to-light, and warehouse automation concepts and ROI evaluation.
Reporting and dashboarding experience (Power BI, Tableau or equivalent) to create actionable visualizations.

Soft Skills

Clear, persuasive communicator able to write concise SOPs, training materials and executive summaries.
Strong analytical thinker who turns data into prioritized actions and measurable improvements.
Collaborative team player who can influence cross-functional partners without direct authority.
Coaching and training ability to upskill frontline teams and improve adherence to standards.
Problem solver with strong root cause analysis discipline and follow-through until sustained resolution.
Time management and prioritization skills in a fast-paced, deadline-driven environment.
Adaptability and resilience to manage change across operations and multiple sites.
Attention to detail with a continuous focus on quality and accuracy.
Customer-focused mindset with an urgency to resolve fulfillment or quality issues.
Leadership presence to lead process-change initiatives and mentor newer associates.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED required.

Preferred Education:

Bachelor’s degree in Supply Chain Management, Logistics, Industrial Engineering, Operations Management, Business Administration, or related field preferred.

Relevant Fields of Study:

Supply Chain Management
Industrial Engineering
Logistics & Transportation
Operations Management
Business Administration

Experience Requirements

Typical Experience Range: 2–5 years of warehouse operations or process improvement experience, including hands-on exposure to WMS and continuous improvement projects.

Preferred: 3–7+ years with demonstrated success in leading process changes, WMS configuration or implementation exposure, and experience working in distribution centers with high-volume order fulfillment. Experience with Lean/Kaizen, Six Sigma training (Yellow/Green Belt) and familiarity with automation technologies is a strong plus.