Achieve Higher Performance with
A Voice-Directed Automated Warehouse Numinagroup.com |
630-343-2600
Define the Use Case
Voice-Enabled
for Warehouse Automation
A key reason companies are investing in warehouse automation is to improve the accuracy and timeliness of managing and moving products and orders more efficiently throughout the warehouse. To reap the return on an investment in automation, it needs to provide substantial operational improvements and value to the customers the business serves. Small and medium size businesses where operators rely on manual workstations to manage parcel manifesting and shipping, that also require operators to manually perform sorting and LTL order consolidation by looking at barcode labels, are examples of operations that will receive a great return on investment if they implement order release optimization and picking automation. Manual processes must be upgraded in order for businesses to remain competitive and lower their dependency on non-value-added human labor running the order fulfillment operation. Labor shortages and errors in
manual processes are expensive and need to be eliminated across the DC by implementing more efficient order fulfillment processes that lower the use of manual labor and increase pick, pack, and ship efficiency. This is the reason Numina Group developed our Real-time Distribution Software, RDS Victory Voice Suite,™ a family of warehouse automation modules using advanced voice recognition technology, including Zebra’s Android based family of mobile wearable touchscreen computers and hands-free barcode scanners, to improve the productivity of order picking and other warehouse work tasks. Voice directions keep operators performing work hands-free and eyes focused with fast, easy to follow voice commands from light-weight ergonomic headsets, and hands-free barcode scanning that enforces repeatable efficient warehouse work practices throughout the DC.
ORDER RELEASE + CARTONIZATION INCREASES ORDER PICKING EFFICIENCY Optimized batch picking of split case and case picks, results in 50% less fork truck travel and wasted operator walk time within the order picking process. Cartonization software to direct picking of items directly to the shipping carton significantly reduces packing labor.
OPTIMIZED WORKFLOW
1
This white paper explores 5 KEY WAYS RDS Voice Suite manages both order release and directs workers in an optimized workflow to lower labor costs, deliver higher productivity, and increase order throughput improvements throughout warehouse operations. WAVE ORDER RELEASE + CARTONIZATION INCREASES ORDER PICKING EFFICIENCY
by adding automated wave or continuous order release, cartonization, and optimized batch item picking to the optimal shipping carton. The Voice Suite combines optimized order wave creation and performs either supervisor-initiated wave release or continuous order release in combination with an advanced order cartonization function. This module takes into account each items’ cube, weight, and compressibility factors to select the right size carton, then performs a pack simulation to verify that all the items fit in a polybag, padded shipper or a single carton, or the right combination of multiple cartons. The advanced cartonization logic can lower annual freight delivery costs 15% to 20% beyond a simple fluid fill cartonization model.
Wave order release also includes delivery prioritization rules for LTL and parcel carrier pick-up times to eliminate missing customer required same day deliveries.
2
ORDER PICKING CAN ACCOUNT FOR 50% OF LABOR COSTS IN WAREHOUSE ORDER FULFILLMENT
We’ve applied our 20+ years of order picking know-how to bundle several advanced picking applications into the RDS Victory Voice Suite. The voice directed picking software enforces several lean, low touch, processes to manage most order picking requirements found in an E-Com, B2B, and Omni-channel Warehouses. RDS Voice eliminates the burden and reliance on reading check digits at storage bins to confirm a pick. At the scan of the product item barcode, the operator hears the unit of measure for each required pick. If the barcode is missing or damaged the operator uses the touch screen display to view the item pick instruction descriptor and product image display. Voice messages keep operators on task with each pick, move, and put task, reinforced with voice message confirmations and the ability to use the message display to handle an exception condition. The operator’s actions are captured to measure their performance relative to the picking task, and supervisor configured work zone standards that are included with the RDS suite’s labor reporting productivity module. RDS Voice requires zero voice training with lean short voice commands prompting each work transaction. Barcode scanning validates most of the confirmation action requirements. New employees become productive in as little as 15 minutes. Voice increases accuracy and speed, making your business more competitive and drives higher customer satisfaction. The time it takes to get a new employee up to speed using RDS Voice is minutes, versus manual paper picking, RF, or traditional voice technologies that take hours to master a single work task, and weeks to become proficient across all the warehouse operations.
Exception handling is part of the voice application, so if the barcode is damaged, or the product lacks a barcode identifier, the operator can view an image of the item along with the product description. Visual verification and touch screen confirmation with location or item barcode scan validation provides the highest accuracy in operations when picking a mix of single items, inner-pack, and cases within the same warehouse zone.
3
THE RDS SUITE OF PICKING APPLICATIONS MANAGE VIRTUALLY ANY WAREHOUSE’S REQUIREMENTS
The majority of distribution operations require some mix of the following order fulfillment operations: E-com, B2B, retailer, wholesaler distribution. This means the WES-WCS software needs to have the functionality to manage Omni-channel fulfillment operations in order to pick and ship a daily mix of parcel and LTL shipments for distributors, while adhering to the complex rules associated with Amazon and big box retailers. The picking software suite needs to account for picking, packing, labeling, and shipping processes within the same application, while enforcing business rules to synchronize order fulfillment operations across the entire warehouse. HERE’S A SNAPSHOT OF RDS SUITE’S ORDER PICKING PROCESSES: Batch Order Picking - Simultaneously pick 12-25 or more orders directly to shipping cartons or totes. This is a 40-50% increase in picking efficiency compared to discrete picking operations. Imagine the wasted labor by visiting a location a dozen times a day instead of just once, if all 12 orders are assigned to the same cart, which the RDS logic allows. The Batch Cart order management module eliminates miles of wasted steps from a discrete order picking operation, resulting in 2X faster picking performance rates. Voice, display, and hands-free pick and put with scan validation of each step unites pick and pack validation for a 99.98% accurate process. Batchbot™ Voice Combined with Autonomous Mobile Robots (AMRs) eliminates the need for operators to push the pick carts. Combining voice + AMRs, synchronizes people and robotic batch carts to streamline pick to carton and case picking, within the same application. The AMRs do all the “heavy lifting” handling 25+ orders at a time, and weight loads of 800 lbs., or more! The Batchbot carts eliminate an additional 25% to 30% of walk time compared to manual pushcarts. Operators can now stay focused on high value tasks like picking. When the last pick is confirmed, the AMRs transport and drop the completed carts at the automated pack line. This instantly frees the AMR for the next work assignment. An AMR design using a large capacity de-coupled pick cart as opposed to an AMR with a permanently attached cart can perform more work, and order picking trips per hour, which lowers the quantity of robots required in the operation.
Fork truck, man-up vehicle mixed case, full pallet and over-sized product pick to pallet from rack and floor locations. For mixed case picking, labeling and manifesting can be combined within a single operation! The operator is equipped with a Zebra mobile wearable printer and at the case barcode scan confirmation, the case carrier or retailer compliance label is printed and applied in a single step, boosting productivity 200% compared to a traditional case pick and direct to a manual manifesting and labeling workstation. Pick Module Pick to Conveyors with Order Zone Routing, referred to as people to goods picking, using intelligent barcode-based controls to transport and deliver orders only to pick zones requiring picks. The pick modules can be single level structures or contain a second and third level to increase storage density. The RDS voice software module directs the operator to pick either a single order at a time or up to three orders at a time in a hands-free pick, pack, and validation of items to the shipping carton or speed picking batches of single items into a barcoded tote. Pick modules can combine pick to carton, speed pick of singles and full case picking in the same modules with RDS Victory Voice adding a 30% to 40% boost in picking productivity over a typical mobile RF terminal based application. Depending on the operations SKU quantity and velocity movement, pick modules continue to be an excellent investment for mid to large order volume warehouse operations. Voice Directed Pick-to-Light and Put-to-Light Order Consolidation, lights are energized to confirm either pick to light order picking or put to light, as well as consolidating picks from fast and slow-moving storage zones. Combining lights and voice’s hands-free scanning can be highly complementary technologies in high density A and B mover SKU storage locations to increase unit pick rates to 300 to 400 items an hour. Voice-Directed Pallet Build picked and labeled cartons, full cases, and non-conveyable items are voice directed at the completion of picking to the required pack and ship areas. Operators equipped with the wearable voice computers and hands-free scanners will be directed with a combination of voice, barcode scan confirmation, and the message display to scan, sort, and perform the pallet build operation. Operators’ instructions on the wearable display show the customer pallet height build rules along with the capture of each item included in the pallet content record. When the pallet contents are complete, or the operator determines the pallet is at the proper build height, a voice command closes the pallet, the content is recorded, and the customer’s order label is printed and applied by the operator.
4
RECEIVING, PUT-AWAY, REPLENISHMENT MOVES
RDS Victory Voice works equally well in moving goods from the dock to reserve and forward storage locations. Voice executes the current ERP or WMS receiving, put-away, and replenishment operations providing 12%-15% efficiency gain with a .3% higher accuracy than an operator equipped with a wearable only mobile computer.
5
GOODS TO PERSON (G2P) OPERATES FASTER
Voice and wearable computers are well suited to further enhance both the putaway and replenishment duties along with directing the operator’s packing productivity for G2P storage and picking solutions. Using a mobile voice and message display as the workstation to manage G2P packing eliminates secondary tote handling, which improves pack operator utilization time by 30% to 50%.
PICK, PACK, AND SHIP IN A SINGLE STEP The RDS Voice Suite has numerous additional features and business benefits to accelerate and enforce higher order fulfillment performance. Equipping your workforce with RDS Victory Voice Suite and Zebra’s family of mobile wearable computers and printers offers a dramatic improvement and rapid return on investment in warehouse productivity. The voice suite easily connects with Numina Group’s Pakt™ pack and ship automation, a conveyor-based pack-and-ship solution that integrates order weight and vision audit, packing, manifesting, and shipping, to further reduce labor and eliminate operation bottlenecks. It’s ideally suited to facilities with a 1,000 to 25,000 mix of re-packed carton and cases a day. Contact The Numina Group to further investigate if the RDS Voice Picking Suite, Pakt automation, or our other warehouse automation solutions can streamline your order fulfillment operation. Let us show you how to lower your labor cost by making your distribution operation a leaner, low touch order fulfillment operation CONTACT US TODAY to start a conversation.
ABOUT NUMINA GROUP Our mission is to help our customers lower their cost per order filled. Decades of industry experience designing data-driven process improvements, matched with the right blend of warehouse automation technologies, drives the highest ROI. The solutions we develop are focused on lowering dependency on manual labor and directing leaner, low-touch processes so that orders are fulfilled faster and error free. Real-time Distribution Software, RDS and our Victory Voice Order Fulfillment Suite make up a comprehensive family of software automation modules to manage an automated pick, pack, and ship warehouse.
Numinagroup.com |
630-343-2600