NuminaGroup

Author: Jen Maloney

  • The Impact of Missing a Cut-Off Window in Distribution and How Numina Group Can Help

    The Impact of Missing a Cut-Off Window in Distribution and How Numina Group Can Help

    Numina Group Blog

    The Impact of Missing a Cut-Off Window in Distribution and How Numina Group Can Help

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    Jen Maloney

    November 15, 2024
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    In today’s hyper-competitive retail environment, order fulfillment success means having a seamless pick, pack, and ship process that matches the various cut-off windows in warehouse operations and carrier pickup times.

    A cut-off window is a deadline for tasks such as receiving, order processing, and carrier pickup, which must be completed to meet customers’ expected delivery dates.

    If cut-off windows are missed, the result is a ripple effect that disrupts order workflows or causes orders to be shipped later for later-than-expected delivery, resulting in severe customer service and financial repercussions for the retailer.

    Blog: The Competitive Advantage of Order Orchestration Technology

    Repercussions of Late Deliveries and Missed Cut-Offs

    The negative impact of order delays due to missed cut-off windows, include the following:

    Customer Dissatisfaction and Lost Revenue

    According to Invespcro, 80% of shoppers surveyed want same-day shipping, while 61% want their packages even faster — within 1-3 hours of placing an order. Additionally, customers want their items to be shipped correctly, on time, and with real-time visibility into the order as it is processed and shipped.

    Industry statistics show that up to 30% of customers will not return to a retailer after a negative experience, such as late delivery. The potential loss of lifetime revenue from dissatisfied customers can add up quickly, resulting in millions in lost business for larger retailers and distributors.

    How much does it cost to replace a lost customer? Studies suggest that acquiring a new customer can cost five to seven times the cost of retaining an existing customer.

    Retailer Compliance Fines and Chargebacks

    Retailers frequently impose financial penalties or chargebacks on vendors or suppliers who fail to meet predetermined terms on delivery requirements for both early or late deliveries.

    Retail non-compliance fines may result in a 1% to 5% added charge¹ added to the order, and when multiplied across thousands of orders, can profoundly impact the vendor’s profit line. These penalties can range from several hundred to thousands of dollars per infraction.

    Chargebacks are particularly common in industries like consumer-packaged goods (CPG) and retail operations, where on-time delivery is critical for maintaining shelf stock and preventing stockouts.

    Increased Customer Service Costs

    If a shipment error does occur, one of the most critical steps to take is creating an accessible, responsive customer service program to help customers resolve the issue as amenably as possible. However, the process of addressing the complaint, researching and identifying the root cause of the problem, and developing a solution is often time-consuming.

    It requires the efforts of staff across multiple departments. The extra time needed by staff to resolve each shipping delay is time-consuming process and adds to operational costs.

    Unplanned Carrier Charges, Higher Shipping Rates and Additional Fees 

    Missing carrier cut-off times may lead to additional shipping charges if companies must expedite late orders using premium shipping services to meet delivery deadlines. These added shipping expenses erode profit margins and increase operational complexity.

    How Numina Group Can Help 

    The Numina Group offers a flexible, real-time warehouse execution platform, RDS™ Warehouse Execution System (WES), offering a family of modules that can be configured to eliminate potential gaps or bottlenecks and create a predictable, smooth-flowing operation.

    Automated Order Processing
    Numina’s RDS™ WES platform is designed to bolt on to any ERP or WMS system and added AI-supported capabilities to automate and synchronize all activities from order analysis, release optimization planning, picking, packing, shipping, and fulfillment.

    RDS serves as the control center that directs the movement of the various connected warehouse technologies and labor resources used in fulfillment operations. It prioritizes orders, selects the optimal picking methodology, and releases according to time constraints to meet cut-off windows. RDS ensures that high-priority shipments are processed ahead of the deadline.

    Enhanced Picking and Packing Automation
    RDS also includes planning logic to assess order profiles and determine the best picking strategy for orders, including batch and discrete picking. RDS identifies the optimal pick path for workers, resulting in shorter pick paths that eliminate excess walking.

    RDS also enables technology-supported voice technology, pick-to-light, and AMR batch-picking solutions for faster, 99.9% accurate picking. RDS cartonization logic can also be applied to auto-determine the ideal shipping carton for an order, making it possible to eliminate the step of picking to totes and replacing it with picking directly to the carton.

    When these strategies are deployed, labor-intensive tasks are eliminated, leading to a 70% reduction in labor costs.

    Carrier and Shipment Manifesting Integration
    The RDS platform is integrated to exchange information with multiple LTL, parcel, and postal carriers for routing, rating, shipment manifesting, and coordination of fulfillment tasks within the time constraints to meet carrier pickup cut-off times and ensure that all shipments are prepared and loaded for on-time dispatch.

    99.9% Accurate Orders and Fewer Returns
    Order accuracy is the cornerstone of creating an efficient fulfillment workflow that will automatically manage activities to meet delivery requirements. The RDS Victory Voice Suite is a modular pick-by-voice solution that guides workers through picking activities via a headset, wearable computer, and hands-free barcode scanning.

    Numina’s advanced voice-picking solution is proven to deliver an order accuracy rate of 99.9%, which has enabled many companies to dramatically reduce shipment errors and customer service calls while lowering the occurrence of returns and reshipments.

    Boost Efficiency and Avoid Costly Shipping Errors

    The Numina Group, an independent warehouse systems integrator and software provider, can help you evaluate your warehouse operations, identify process improvements, and evaluate warehouse technology solutions that will create a seamless, end-to-end warehouse execution workflow that drives accuracy and profitability.

    With more than 40+ years of experience working in thousands of facilities, we are uniquely qualified to assess your current operations, provide expert warehouse consulting services and make vendor-neutral recommendations for the best combination of technologies that will meet your strategic business goals.

    Contact us today for a complimentary onsite consultation to discuss your needs.

    About the Numina Group

     

     

     

    ¹ Weber Logistics, blog, “Chargebacks in the Retail Industry”

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  • Why AMR Cart Payload Capacity Matters in Warehouse Operations

    Why AMR Cart Payload Capacity Matters in Warehouse Operations

    Numina Group Blog

    Why AMR Cart Payload Capacity Matters in Warehouse Operations

    Picture of Jen Maloney

    Jen Maloney

    October 14, 2024

    Choose the Right Size to Maximize Order Picking Efficiency

    Autonomous mobile robots (AMRs) are becoming increasingly common in warehouse operations as a flexible, more cost-effective technology option than traditional product storage and retrieval and other goods-to-person solutions.

    Among the many benefits AMRs offer, companies are choosing them because:

    • AMRs can be rapidly deployed within the storage aisles of existing facilities and offer a cost-effective technology option for new facilities.
    • AMRs, when combined with voice-picking technology, increase picking productivity by 2X or 3X.
    • AMRs, as a goods-to-person solution, reduce manual labor and increase job satisfaction, lowering turnover.

    (Blog: Goods-to-Person Solutions for Companies of All Sizes)

    Multiple AMR Options Available

    With such promising results, many companies are now interested in AMR technology. The good news is that buyers can now choose from a broad selection of AMR models to determine the most efficient and cost-effective for their fulfillment requirements.

    One of the most important factors is the AMR’s payload capacity. A larger payload capacity AMR can manage a larger workload than smaller AMRs, reducing the number of AMRs required to accomplish the same work.

    Numina Group’s large capacity RDS™ AMR Batchbot™, compared to the capacity limits of smaller AMRs, is proven to deliver enhanced productivity, better resource utilization, and, ultimately, improved profitability. AMR Batchbot also reduces the number of AMRs required to achieve throughput goals, resulting in a lower technology investment requirement.

    AMR Payload Capacity Ranges

    Payload capacity is the maximum weight that can be loaded onto an AMR during fulfillment before it needs to be off-loaded and re-inserted into the workflow. Large-capacity AMRs deliver the following benefits:

    1. Higher Carrying Capacity: Small AMRs have roughly a 250-lb. capacity, while an RDS AMR Batchbot has a 6,000-lb. capacity, resulting in fewer trips and less time required for order picking and transportation.
    2. Multiple Picking Scenarios: Large capacity carts enable workers to handle more picking locations within a single trip. Smaller AMRs typically handle 6-12 picking locations, while AMR Batchbots can cover 25-30 locations in a single trip, an immediate positive increase in throughput.

    Comparison: Small AMR Bots vs RDS Batchbot 

    To highlight the advantages of larger payload capacity, consider the following infographic that contrasts small AMR applications with Batchbot picking applications:

    Efficiency Gains from RDS AMR Batchbot

    • Higher Pick Rates: Warehouse workers can pick 250 to 400 items/worker/hour when they work alongside, significantly more than lower AMR pick rates of 90-150 items/worker/hour .
    • Greater Equipment Utilization Rates: Idle time is greatly reduced due to the flexibility of RDS AMR Batchbots, which can be configured for constant motion to self-direct to pack stations and back into the picking workflow – eliminating downtime. Smaller AMRs, in contrast, experience up to 25% idle time due to unloading.
    • Accommodates Multiple Picking Types: RDS AMR Batchbots can be configured to manage multiple picking types such as case, each, unit picking, and full pallet movement. This eliminates the need for multiple specialized robots to pick.

    Visual Representation of Scale

    Watch the video below to how a large capacity AMR solution enhances performance and reduces the overall need for additional equipment such as forklifts and smaller AMRs.

     

    Conclusion: Do More with Less

    As with any warehouse technology investment, it is critical to select the right AMR solution to meet your efficiency goals and provide a rapid return on investment. Numina Group’s large capacity RDS AMR Batchbot solution, managed by our RDS Warehouse Execution and Control System, results in higher order throughput levels in less time and lower equipment and labor costs.

    Ready to Learn More?

    Numina Group provides end-to-end, expert warehouse design, engineering, goods to person and AMR selection and system implementation services.

    Talk to one of our warehouse automation experts to learn how Numina works with customers in a collaborative manner to define process improvements and select the right blend of automation to drive the highest productivity at your operation. 

    Contact us today for a complimentary consultation about our RDS AMR and other goods-to-person solutions.

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  • How Overtime & Temporary Staff Costs Hurt Distribution Centers—and How Numina Can Help

    How Overtime & Temporary Staff Costs Hurt Distribution Centers—and How Numina Can Help

    Numina Group Blog

    How Overtime & Temporary Staff Costs Hurt Distribution Centers—and How Numina Can Help

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    Jen Maloney

    October 11, 2024
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    When faced with spikes in order fulfillment volumes, many companies pay overtime or hire temporary warehouse labor to get orders out the door. However, while both methods enable the company to meet delivery requirements, they add to operational costs and erode profitability.

    The Many Hidden Costs of Overtime and Temporary Labor

    For permanent employees, overtime wages, while alluring, do not erase the strain of excess hours worked, which can lead to lower productivity, risk of job-related injuries, and a higher occurrence of order errors. Employee job satisfaction erodes when overtime conditions for an extended period and high turnover rates begin to occur. No wonder many warehouse operations are in an endless, costly loop of recruiting, hiring, and training new workers.

    Video: How Rainbow Resources Reduced Labor Costs with Pick, Pack and Ship Automation

    When temporary staff is brought in, the company must also take on added training costs, which often results in pulling high-performing employees into a training role. Also, temporary workers’ productivity levels are usually lower than that of permanent staff, and they require additional supervision. Inconsistent performance and frequent training further erode operational efficiency, leaving distribution centers with high costs but subpar results.

    These potential circumstances are sure to impact order accuracy and customer satisfaction.

    Dramatically Reduce Labor Costs with Warehouse Automation 

    Many of today’s businesses have identified warehouse automation as the most cost-effective way to keep up with growing order volumes without increasing labor costs. Warehouse automation allows for easy scalability of resources to increase throughput as the business grows.

    Numina Group’s Tier I RDS™ Warehouse Execution and Control System streamlines order fulfillment operations by eliminating manual tasks and replacing them with a high-speed, low-touch automated pick, pack, and ship workflow that can be adjusted and expanded to handle increased demand without significant additional investments.

    Technology as a Force Multiplier
    In a manual or semi-manual order fulfillment processing environment, productivity increases are typically limited by human capabilities. Warehouse technology to automate order fulfillment, in contrast, is a force multiplier that far surpasses the order fulfillment output of manual or semi-manual warehouse processes.

    For example, workers in traditional warehouses have picking ranges between 50 and 100 per hour. When paper-based picking is replaced with Numina’s RDS WES-WCS voice-picking technology, the same workers’ picking rates can be increased by 70% or more.

    In fact, several Numina clients have increased workers’ picking rates to 230-300 lines per hour in high-velocity, properly SKU-slotted pick zones. They have also reduced recurring annual overtime and seasonal labor costs, further accelerating the ROI gained on their warehouse automation solution.

    Case Study: Schumacher Triples Throughput in Existing DCs with a 12-Month ROI in Warehouse Automation

    During slower order demand periods, RDS Voice Picking can direct operators to pick zones with the highest demand between two or more zones to minimize downtime and boost productivity per employee.

    Green Rabbit, a cold chain 3PL, has quadrupled order throughput by replacing manual procedures with warehouse technology. “We’ve at least doubled output in the original Massachusetts facility with the same headcount and have nearly tripled output in other facilities as business has grown,” said Green Rabbit’s Director of Operations.

     

    Get Started with the Numina Group 

    Learn how Numina Group can help you transform your distribution center into a streamlined, automated operation. Numina is differentiated from other warehouse automation companies by our comprehensive solutions and services:

    Numina Group provides clients with a consultative design approach that uncovers and defines better processes, operational improvements, and identifies technologies that reduce labor costs, and improve storage and space utilization.

    Contact us today for a complimentary onsite consultation to discuss your needs.

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  • The High Cost of Shipping Mistakes and the Path to Perfect Order Practices

    The High Cost of Shipping Mistakes and the Path to Perfect Order Practices

    Numina Group Blog

    The High Cost of Shipping Mistakes and the Path to Perfect Order Practices

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    Jen Maloney

    October 4, 2024
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    Shipping mistakes cause customer frustration, resulting in serious damage to any e-commerce company or retailer. Shipping mistakes are also expensive in terms of the internal resources required to process returns, correct errors, and also the revenue lost from non-returning customers. Research shows that 30% of shoppers who have had a negative experience with a retailer will not return and will likely buy from a competitor.

    Blog: How End-to-End Warehouse Automation Can Future-Proof Your Company

    Also, shipping errors are not limited to delivery delays but can include errors in the items shipped. For example, research suggests that the cost of miss-picks drops an e-commerce company’s profits by $400,000 or more.

    Eliminate Shipping Errors with a Perfect Order Culture

    One way to minimize the risk of order and shipping errors is to build your fulfillment operations around the concept of a “perfect order,” which is defined by four key metrics:

    • Complete order-fill accuracy
    • Zero defects
    • Accurate documentation
    • On-time delivery

    Errors related to any of these metrics can result in a dissatisfied customer and lost revenues. However, they can be largely eliminated by analyzing your warehouse operations and making improvements to ensure efficiency and accuracy.

    Video: Warehouse Automation Design for Perfect Order Practices

    Streamlining Distribution Processes

    To minimize errors and improve efficiency, companies should consider the following process improvement strategies:

    • Evaluate Product Slotting: Perform slotting analysis to ensure that product placement is optimized to maximize picking efficiency. (Blog: What is Slotting in a Warehouse? Tips to Optimize)
    • Batch Order Picking: Increase efficiency by grouping similar products by location, enabling workers to pick multiple orders simultaneously.
    • Plan for Seamless Expedited Order Management: Configure your order processing worklow to allow for the seamless insertion of expedited orders into the overall fulfillment workflow.
    • Analyze and Segregate Task Management: Identify and divide the various tasks in the order workflow and assign them to multiple workers. By doing so, you can prevent the reliance on one person and spread quality control across the team.
    • Implement Batch Picking with Consolidation Walls: Optimize the picking process to reduce handling time.

    The above recommendations are just a few ways to streamline your distribution operations. Depending upon your company’s product profile, other efficiency options and warehouse technology can be deployed to speed up order fulfillment while maintaining 99.9% order accuracy.

    The Role of Warehouse Execution Software 

    Software is essential to increase order fulfillment productivity and throughput. WMS and ERP software systems commonly play an integral role in warehouse operations but often cannot be easily or quickly integrated to manage other value-added warehouse technologies.

    As a result, most businesses are seeking warehouse execution and control software to extend the functionality and life of their WMS/ERP systems. Numina Group’s RDS™ Warehouse Execution and Control Software offers a suite of modules designed to improve the entire pick, pack, and ship process, including:

    These modules can function independently or together to create a cohesive solution that upholds perfect order practices. Numina Group stands out by offering the flexibility of these components combined in a singular software suite.

    Conclusion

    Warehouse automation, when managed by a flexible WES-WCS platform that integrates and synchronizes workflow using technologies such as those discussed above, offers the most compelling results in controlling operating costs, and optimizing warehouse operations for current and future growth.

    Numina Group can show you how to define, design and implement the right combination of warehouse technologies for your operations. Our warehouse automation design services, warehouse automation software, and extensive systems integration expertise deliver solutions proven to execute complex order fulfillment requirements that improve warehouse productivity and enhance customer service.

    About the Numina Group

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  • How to Optimize Your Warehouse to Improve Peak Season Performance and Prepare for a Successful Automation Project

    How to Optimize Your Warehouse to Improve Peak Season Performance and Prepare for a Successful Automation Project

    Numina Group Blog

    How to Optimize Your Warehouse to Improve Peak Season Performance and Prepare for a Successful Automation Project

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    Jen Maloney

    October 3, 2024

    Despite the uncertainty brought on by inflation, labor shortages, and a potential recession, this year’s peak holiday shopping season is still expected to be robust as consumers continue to look forward to the holidays. This year’s peak season could offer your business an opportunity for growth if you’re ready.

    Gartner suggests that preparing in advance by developing a solid omnichannel fulfillment strategy is essential to success. By taking a proactive approach, you can optimize your operations in advance to ensure a smoother, more profitable fourth quarter.

    Retailers need to optimize their fulfillment workflows for efficient picking, packing, and shipping processes to handle the rapid surge in omnichannel order volumes in peak season. Warehouse automation can also help to manage the complexities of fulfilling orders across multiple channels, ensuring speed, accuracy, and scalability.

    It may be too late to fully optimize your distribution center with new automation technologies before the holiday peak, but that doesn’t mean you can’t take meaningful steps now. As a first step, closely track bottlenecks in your operations, such as delays or order inaccuracies, to identify areas for improvement and ensure the following year runs more smoothly.

    By observing and documenting these pain points, you will be well-prepared for what needs to be automated or streamlined for current operations and ready to identify and implement warehouse technologies to improve future growth.

    Learn About Numina Group’s Warehouse Optimization Services

    How to Prepare Your Distribution Center for Peak Season

    Based on Numina Group’s experience in thousands of warehouses throughout North America, here are some suggestions that you can act on now to ease tension during peak season. Our warehouse experts can also assist you in optimizing your distribution and ensuring successful deliveries. 

    1. Evaluate Slotting Processes: Analyze SKU movement and optimize storage to reduce pickers’ travel time. Consider batch picking for high-demand products to increase efficiency.
    2. Lean Up Packing Operations: Pre-make and stage popular carton sizes to eliminate packing delays and improve throughput.
    3. Limit Congestion: Implement frequent replenishment to avoid workflow obstructions and ensure temporary workers can navigate the space efficiently.
    4. Calculate Staffing Needs: Plan seasonal hiring early and allow ample training time so your best employees can focus on critical tasks during peak season.
    5. Update and Streamline Staff Training with Automation: Voice-directed picking systems, like Numina’s Victory Voice™, accelerate training and onboarding by enabling hands-free, voice-guided tasks, increasing picking speed and accuracy with minimal training.
    6. Preventive Maintenance and Spare Parts Management: Conduct a systems audit and stock up on essential spare parts to prevent costly downtime.
    7. Plan for the Future: After the peak season, audit your operations and identify bottlenecks. Investing in automation solutions for the long term, such as voice-picking technology, mobile robots, and RDS™ Warehouse Execution and Control Software platform, will streamline your processes and reduce labor dependence year-round.

    Numina Group will work closely with your company to review, compare, and select the right blend of process improvements and the best warehouse automation technology to optimize order fulfillment operations.

    Learn More

    Video: Automation Integration Walk Through – RDS Warehouse Execution System

    Video: How Merit Medical Increaseed Productivity 200% with Warehouse Automation

    Blog: Order Picking Automation Technologies to Resolve Warehouse Labor Challenges

    Blog: The Basics of Warehouse Automation

    Contact us to schedule an on-site warehouse assessment before peak season responsibilities fill your calendar.

    Contact us

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  • Achieve the Industry’s Highest AMR Picking Rates with RDS Batchbot

    Achieve the Industry’s Highest AMR Picking Rates with RDS Batchbot

    Numina Group Blog

    Achieve the Industry’s Highest AMR Picking Rates with RDS Batchbot

    Picture of Jen Maloney

    Jen Maloney

    September 4, 2024

    Achieve the highest AMR picking rates in the industry with RDS™ AMR Batchbot, Numina’s new, high-capacity batch-picking solution that combines AMRs, pick-by-voice technology, and wearable computers.

    RDS AMR Batchbot Benefits:

    • Achieves pick rates of 350 lines/worker/hour
    • Reduces labor requirements
    • Accelerates order pick and pack processes
    • Increases order accuracy to 99.9%
    • Enables same-day delivery

    Customer Video: See AMR Batchbot in Action

    In this short video, see how our customer, NorthShore Care Supply, DOUBLED picking productivity with RDS AMR Batchbot:

    WATCH VIDEO

    How to Choose the Right AMR Picking Solution for Your Operations

    Learn more about AMR Batchbot and how it can revolutionize your fulfillment operations in our blog: 5 Compelling Reasons to Consider Numina’s AMR Picking Solution for Your Warehouse

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    Product: Learn More About RDS AMR Batchbot

    System Integrator Insight: Factors to Consider in Evaluating AMRs for Your Distribution Operation

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  • 5 Compelling Reasons to Consider Numina’s AMR Picking Solution for Your Warehouse

    5 Compelling Reasons to Consider Numina’s AMR Picking Solution for Your Warehouse

    Numina Group Blog

    5 Compelling Reasons to Consider Numina’s AMR Picking Solution for Your Warehouse

    Picture of Jen Maloney

    Jen Maloney

    August 19, 2024

    Recognizing the order fulfillment productivity gains achieved with autonomous mobile robots (AMRs) and other robotic-based goods-to-person (G2P) (GTP) technologies, the Numina Group developed RDS BatchBot™ AMR picking module, a module of its RDS™ Warehouse Execution Software (WES) platform.

    RDS: Unite Workers with Robots and Wearable Technology to Achieve the Industry’s Highest Picking Rates

    RDS AMR Batchbot unites AMRs and people to yields the highest picking rates in the industry – 350+ items/workers/hour!

    Numina’s RDS AMR BatchBot solution arms workers with large-capacity AMRs, mobile wearable computers, wireless headsets, and hands-free barcode scan validation for fast, accurate picking.

    Workers work alongside AMR mobile robots that hold each, case and pallet-picked orders and eliminate the fatiguing task of manually pushing heavy carts.

    Numina’s RDS WES software platform synchronizes the AMRs and wearable technologies to create a streamlined workflow and support seamless warehouse orchestration for all fulfillment tasks.

    By combining voice technology and AMRs, operators’ work tasks are unified across warehouse operations, and productivity is doubled while operators perform at the highest single-touch picking accuracy available.

    Following are five compelling benefits that Numina’s RDS AMR Picking solution delivers:

    I. RDS AMR Picking is a Flexible and Cost-Effective Warehouse Technology Investment

    Autonomous mobile robots (AMRs) and G2P robotic solutions are fast becoming a go-to technology choice in warehouse order fulfillment operations due to two key reasons:

    • AMRs can be deployed rapidly within existing rack storage aisles or new facilities.
    • AMRs and G2P solutions can be configured to work with people. Overall picking productivity increases by 2X or 3X when voice-picking technology is added.

    Advancements in the latest generation robotic-based (G2P) technologies have lowered technology investment costs, making them a viable option for companies of all sizes.

    As a result, “The latest generation of AMRs and robotic-based G2P is becoming more justifiable for most sizes of distribution center (DC) operations for picking, moving, and sorting of goods,” said Dan Hanrahan, CEO of the Numina Group.

     

    2. RDS AMR Picking Delivers the Benefits of G2P Automation

    From a workflow perspective, AMR picking and other goods-to-person solutions are proven to improve operations in many warehouse operational areas, including the following:

    • Lower labor requirements, reduced operational costs, and less need for temporary staff.
    • Faster pick-and-pack processes.
    • 99.9% picking accuracy when AMRs are combined with voice-picking technology and scan validation.
    • Faster order deployment to support same-day delivery.

    3. RDS AMR Picking Handles Large Batch Carts for Higher Throughputs

    As AMRs continue to evolve, companies can apply AMRs across a broader range of picking requirements. For example, today’s AMRs can move larger payloads than earlier models, leading to even higher throughput with the same staff.

    Some large-capacity AMRs can handle weights of 2,000 or more lbs. and transport optimized batches of up to 25 orders on the cart.

    Large-capacity AMR pick carts can also support picking eaches and full cases on an AMR pick mission more efficiently and at a lower cost than traditional conveyor-based pick modules.

    With Numina’s RDS AMR picking solution, pick operators are equipped with its latest generation, Victory Voice™ Suite, an advanced pick-by-voice technology that directs picking operators in “Meet Me Mode” by using voice instructions to direct the operator to meet the AMR at the required pick location before the AMRs arrival time.

    RDS Victory Voice directs the operator’s movements. It synchronizes with AMR movement simultaneously, resulting in workers and AMR working together faster and more efficiently as they pick a larger batch of orders.

    RDS AMR Picking Yields the Industry’s Highest Pick Rates with 99.9% Order Accuracy

    RDS AMR picking robots transport carts to only those zones that require a pick, based on the RDS Order Release module determining the shortest travel path and selection of orders with like-SKU pick locations. 

    RDS-optimized pick paths eliminate excess walking and reduce the fatigue due to pushing heavy carts.

    The AMR and pick-by-voice solution is faster and more efficient, with voice and hands-free pick-and-put to scan confirmation to cartons and cart shelf positions to achieve 99.9% picking accuracy.

    Results? Productivity increases to 250-to-350-unit picks per operator and hour.

     

    5. RDS AMR Picking Reduces Your Technology Investment

    Large-capacity AMRs can dramatically reduce your technology investment. For example, a fleet of 6 to 7 large capacity AMRs can outperform 25 lightweight 250 lb. capacity AMRs in order picking.

    RDS AMR Picking Highlights:

    • Transport, move, and pick 25+ orders in an optimized travel trip.
    • Large cart AMRs and/or pallet movers have capacities of 2,200 lbs.
    • RDS optimizes cube and load capacity for each-, mixed-case, and pick-to-pallet AMR pick missions.
    • Higher pick density boosts picking productivity per AMR and worker picks per hour for piece-picking and case-picking.
    • AMRs are self-directing and deliver carts to an open pack station or other areas without human intervention. 

    Which G2P is Best for Your Organization?

    Today, companies can choose from hundreds of warehouse robotic technologies and options to implement an AMR picking or other G2P solutions. For the best project results, it is wise to engage a knowledgeable warehouse automation partner such as the Numina Group and undertake a design-first approach to determine which GTP solution best suits your warehouse operation.

    If your product profile is a good fit for a G2P system, the next step is to evaluate available options and determine which is best for your mix of products, picking, and storage needs. The results should be documented in a warehouse automation design plan to ensure successful project results.

    Blog: Cost and Performance Benefits Offered by the Latest G2P Warehouse Robot Solutions

    The Numina Group will work closely with your company to review, compare, and select the right blend of conveyors, AMRs, and G2P automation technologies to find the best technology to optimize your order fulfillment operations.

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  • Retailer Increases Picking Productivity by 35% and Accuracy to 99.9% with Numina Warehouse Automation

    Retailer Increases Picking Productivity by 35% and Accuracy to 99.9% with Numina Warehouse Automation

    Numina Group Blog

    Retailer Increases Picking Productivity by 35% and Accuracy to 99.9% with Numina Warehouse Automation

    Picture of Jen Maloney

    Jen Maloney

    June 13, 2024

    A leading specialty retailer with over 250 retail stores knew that it could significantly boost order fulfillment productivity with warehouse automation.

    The question was, which technology would offer the company the best performance results and ROI?

    The team contacted the Numina Group, an independent warehouse systems integrator, to explore its options.

    Challenge

    All the retailer’s store and e-commerce orders were fulfilled in its 350,000-square-foot distribution center (DC), which manages 1 million active SKUs and a high daily order volume. Sales represented 90% of the DC’s order fulfillment volume, with e-commerce sales accounting for the balance.

    The warehouse operation relied on a primarily manual paper-based picking process that required picking and replenishment from random forward high-density pick shelf locations. Workers used paper pick tickets and price label sheets to manage the picking and to apply price labels across four main pick zones.

    Workers would follow paper instructions to pick discrete orders and manually apply price labels on each item picked for a single store in each zone. Picks per store would range from 30 to 300 items into a series of totes.

    At pick completion, the totes were placed on a conveyor that transported and sorted the totes to each store’s specific staging and shipping area. Approximately 63 retail store orders are picked each day. Stores typically receive 35 to 40 totes, while larger stores receive up to 175.

    This labor-intensive process was a drain on the company’s profit margin.

    Blog: Order Picking Automation Options to Resolve Warehouse Labor Shortage Challenges

    Embarking on the Order Fulfillment Process Design Study

    Numina Group first performed a process design study to benchmark current performance and determine which technology was the best investment to increase order fulfillment productivity.

    During the warehouse design study, Numina warehouse engineers collaborated with the company’s logistics executives and operation team to review its current picking and store delivery processes, identify areas for improvement, and then define and flowchart a leaner process that would streamline and improve the picking operation.

    The team also reviewed possible technology options. It quickly became apparent that a multi-modal voice-picking solution that combines voice commands and responses with barcode scanning to direct and validate workers’ tasks in the pick-and-pack fulfillment operation could meet productivity improvement goals and provide a one-year ROI.

    Solution – RDS™ WES-WCS with Victory Voice™

    The Numina Group was hired to implement its Real-time Distribution System (RDS™) Warehouse Execution System (WES) and RDS Victory Voice™ Suite. RDS is integrated to exchange real-time information with the company’s WMS – JDA Merchandise Management solution.

    The RDS Victory Voice Suite is an integral component of the RDS WES platform. It can be deployed as a voice-directed application for warehouse picking, replenishment, and inspection applications. It can also be combined with other warehouse technology, such as automated conveyors, packing automation, and print-and-apply labeling for end-to-end order fulfillment automation.

    Victory Voice includes flexible, configurable functionality that extends beyond traditional systems. For example, at this customer’s retail distribution center, it added wave pick optimization and batch picking in addition to the store item price label printing to the existing WMS.

    Victory Voice manages the batch cart pick process and balances order picking across the pick zones.

    Voice-Directed Picking Process

    The retail fulfillment voice-directed pick process is closely coupled to the WMS and works like this:

    • The WMS system sends the store order picking details and item location map to RDS.
    • RDS builds order waves of 1 to 6 store batch carts optimized for the most efficient operator walk paths to eliminate unnecessary steps.
    • RDS sends the pick plan to the WMS to batch print store tote ID labels and item price labels that match the walk path order for each store.
    • Voice commands direct the operators for cart loading in the cart pick zones and at the high-volume, fastest-moving SKU zone, which uses a pick-and-pass conveyor process.
    • RDS directs workers through voice commands received via a headset, combined with a wearable mobile computer to complete tasks.
    • Pickers perform each voice-directed picking and labeling task hands-free – eyes focused!
    • At each location, the operator is prompted with the pick location and verifies the location by scanning the check digit, which causes a voice prompt for the quantity pick of the required item.
    • At pick completion, the operator uses the voice response “OK” to validate the quantity picked.
    • RDS Voice then directs the picker on the placement of the items to the store-specific tote.
    • RDS returns all pick transactions to the WMS for inventory records and provides data for labor management and operational productivity reporting.
     

    Pilot Project Resolves Questions, Exceeds Performance Expectations

    Because the workforce had never used voice-picking technology, the customer had concerns about their workers’ adoption of voice technology and the voice-picking solution’s ability to achieve the estimated ROI.

    The company’s original goal was to increase average picks by 30% per hour, from 195 lines to 257 lines, with automation. “We had to prove to ourselves that we could get a 30% productivity gain before we deployed it to the entire workforce,” said the operations manager.

    A pilot implementation was initially conducted with 20 pickers to prove its viability. After the initial success, the trial period was expanded to 40 pickers, eventually to all 100 workers.

    • During the pilot, a 20% productivity increase occurred on the first day due to the ease of learning facilitated by RDS Victory Voice’s speaker-independent voice technology.
    • Within weeks, the workforce had exceeded the 30% goal.
    • Workers soon advanced above a 35% productivity increase, with the highest-performing workers achieving a 60% productivity increase.

    “At the same time, we identified several additional enhancements that would yield even higher productivity when the solution was deployed to our entire workforce,” the operations manager said.

    Order Picking Accuracy Increases to 99.9%

    Paper-based picking can lead to product mispicks, quantity errors, and order problems. By eliminating paper-based picking, RDS has enabled the company to eliminate picking errors and improve order accuracy.

    The RDS solution’s voice-enforced pick and pack processes, combined with barcode scan validation, have prevented picking item and quantity errors, resulting in a smooth, single-touch process with 99.9% accuracy rates.

    Video: 99.9% Order Picking Accuracy with RDS Victory Voice

    RDS Labor Tracking Provides Tracking to Support Employee Incentive Program

    The company also took advantage of RDS labor management and reporting tools to further boost workforce performance. RDS adds operator accountability through Web-based labor management tools that record the accuracy and performance of the operators.

    These RDS features allow the management team to view operational productivity from any PC, tablet, or portable device, with real-time production statistics for any worker. Views and reports provide worker performance feedback that displays individual and team hourly and daily production results. This real-time reporting capability has proven beneficial in recognizing and rewarding workers who exceed their goals.

    Blog: Labor Tracking & Performance Metrics of Voice Picking

    “Once we started tracking the labor productivity measurements, we saw that some of our associates were excelling,” said the operations manager. “This prompted us to put in an incentive program for our workers. If they maintain an accuracy level of at least 99.6% and reach at least a 30% higher productivity level than the designated standards, they qualify as a Voice Professional (VP), which earns them recognition within the order-picking team, as well as a wage increase as part of our bonus plan.”

    Summary

    By deploying Numina’s RDS WES and Victory Voice Suite, the retail company has successfully met and surpassed its productivity goals, increased order accuracy to 99.9%, and gained a valuable labor tracking tool that has opened the door to new employee incentive programs.

    With Numina’s scalable solution, the company can quickly respond to surges in order volume without adding to headcount.

    ###

    The Numina Group is a top-tier designer and integrator of warehouse automation solutions, offering decades of experience in warehouse design, warehouse software, material handling equipment, systems integration, and implementation services for mid-to-large-sized enterprises.

    Our team has designed and successfully implemented over 1,000 warehouse automation projects in diverse warehouse environments throughout North America.

    Contact us to schedule a complimentary on-site warehouse assessment today.

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  • E-commerce Fulfillment Technologies with Rapid Efficiency & ROI Results

    E-commerce Fulfillment Technologies with Rapid Efficiency & ROI Results

    Numina Group Blog

    E-commerce Fulfillment Technologies with Rapid Efficiency & ROI Results

    Picture of Jen Maloney

    Jen Maloney

    April 25, 2024

    Testimonies abound about how e-commerce is the go-to strategy for companies to reach new markets and quickly boost sales revenues. Not surprisingly, the predicted growth of online retail sales is expected to far outpace traditional brick-and-mortar store sales for the foreseeable future.

    According to a report by Business Insider Intelligence, e-commerce sales accounted for 15% of all retail sales worldwide in 2021 – up from just over 10% in 2017. As we have seen, surges in e-commerce can come from exposure to new markets, new shopping platforms, social media influence, and sudden changes such as the pandemic.

    As a result, virtually all retailers and retail suppliers are adapting their operations to manage e-commerce order fulfillment. Many are grappling with the pivotal question of cost-effectively handling online orders’ exponential growth, adapting their existing facilities, and/or designing new operations to manage omnichannel fulfillment efficiently.

    Is Your Distribution Operation E-Commerce Ready?

    The challenge lies in ensuring your distribution center is ready to efficiently and cost-effectively manage e-commerce fulfillment. Adding e-commerce order fulfillment to an existing DC operation can be complex, mainly because e-commerce orders have a markedly different order profile than orders shipped to retailers and B2B operations.

    Blog: Key Factors in Integrating Traditional and E-Commerce Order Fulfillment Operations

    However, steps can be taken to resolve these challenges and convert a traditional distribution operation into an omnichannel warehouse automation solution that efficiently handles business-to-consumer (B2C) and B2B orders.

    The question is, where to begin?

    It is well-documented that the order-picking process is typically the most labor-intensive and costly process in a distribution operation, making it the obvious first place to evaluate. Picking operations make up 50% or more of total warehouse labor costs when accounting for order picking, quality control, and packing activities.

    Voice-picking technology or pick-by-voice is one of several proven ways to reduce manual picking tasks, increase throughput, lower labor costs, and increase profitability.

    Blog: The ROI of Voice Picking

    However, once picking is streamlined, the bottleneck often merely shifts to the packing and shipping area, which, without automation, cannot absorb the workflow.

    This pinch point prevents companies from realizing building-level throughput improvements achieved by optimizing order picking.

    Eliminating The Bottleneck in the Final 100 Feet of the DC

    Especially for e-commerce order fulfillment, the packing, documentation, manifesting, and labeling process in the last 100 feet of the warehouse is labor-intensive and frequently becomes a bottleneck that slows down throughput.

    By optimizing this post-pick area with automation, e-commerce fulfillment can be handled efficiently alongside traditional fulfillment activities.

    The Availability of Modular All-in-One Pack-and-Ship Solutions

    The Numina Group offers a cost-effective, phased, modular solution such as Pakt™, its all-in-one modular, scalable, post-pick, end-of-line pack-and-ship solution. Pakt is a component of Numina’s RDS™ WES-WCS Real-Time Distribution Solution, a Tier I Warehouse Orchestration Automation Platform offering a family of modules to automate the entire warehouse operation.

    Pakt automates the final 100 feet of a DC’s order fulfillment operation. Pakt includes predeveloped modules that streamline labor and eliminate fulfillment bottlenecks in the pack-and-ship operation.

    Several of Pakt’s automation modules can be implemented all at once or in the combination best for your operations, including:

    • Scan, Weigh, Vision Audit (SWD): To ensure the right products have been picked into the correct shipping container based on weight and provide image-based traceability via cameras.
    • Print, Fold, Insertion (PFI)/Document Insertion: To automatically insert any packing slips, marketing materials, or compliance documentation
    • Void & Auto-Taping: To have rules-based, system-directed void insertion and automatic taping of the shipping container.
    • Print and Apply (PANDA): To automatically manifest, print, and apply labels for shipping, ASN, UCC, packing slips, packing sheets, and more.
    • Shipment Sortation: To automatically sort shipping containers based on parcel carriers, LTL, FTL, and exceptions.

    DOUBLE Order Packing Throughput with a Speed Pack Station

    If your business ships a high volume of single-line e-commerce orders, you can double order packing throughput by implementing a speed-pack station.

    In this configuration, orders are batch-picked to the speed-pack station and scanned directly into a padded bag. The packing sheet is automatically printed and inserted into the bag using the Print-Fold-Insert system, and the carton is sealed and placed on a conveyor.

    The bag is automatically weighed with scan-weigh-dim technology. The weight is passed directly to the carrier’s manifesting system for rate shopping, and the shipping label is printed and applied to the bag. The label is scan verified with RDS’s FDA-rated level of tracking and validation software, then sorted directly to the gaylord.

    Efficiency Gained: Speed-pack padded bag lines can achieve rates of 18 to 24 cartons per minute with a single print-and-apply applicator.

    Evaluate and Plan Before You Act

    Before investing in warehouse automation solutions, working with an independent warehouse systems integrator such as the Numina Group, which is singularly focused on warehouse optimization and automation, is crucial.

    Learn More About Numina’s Systems Integration Services

    The Numina Group can help you evaluate your entire fulfillment process and define a warehouse automation solution comprised of the best technology components for your operations.

    As a first step to reduce project complexity and risk, we perform a detailed engineering assessment with you and make unbiased recommendations to match your business goals. We also have warehouse automation design and engineering services, in-house controls and software, and implementation services to ensure project success.

    During the evaluation step, we assess all aspects of your fulfillment operations, including processes, labor requirements, and technologies. We can also help you identify priority projects and develop a plan.

    For example, based on the evaluation results, you may find it necessary to automate the pack-and-ship area as the initial phase, or if your current picking process lacks the tools to operate an omnichannel operation, we can help you define complete requirements for e-commerce pick, pack, and ship processes.

    Solve Your Warehouse Optimization Needs with the Numina Group

    Whether you envision your operation benefiting from our voice-directed picking solution or all-in-one pack-and-ship solutions such as Pakt, think Numina Group.

    Contact us today to discuss phase one of defining the right blend of automation to accelerate your DC’s performance.

    Contact us

     

     

     

     

    [i] Online Retail Sales: Retail e-Commerce Sales Growth from 2023 to 2030.

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  • Key Factors in Integrating Traditional and E-Commerce Order Fulfillment Operations

    Key Factors in Integrating Traditional and E-Commerce Order Fulfillment Operations

    Numina Group Blog

    Key Factors in Integrating Traditional and E-Commerce Order Fulfillment Operations

    Picture of Jen Maloney

    Jen Maloney

    April 4, 2024

    The convenience of e-commerce or online shopping is firmly entrenched in consumer shopping habits and continues to take up a growing proportion of total retail sales.

    As noted by Shopify, from 2021 to 2027, annual global e-commerce sales are projected to increase by $3 billion, marking an overall increase of 61.1% and an average annual growth rate of 8.3%.[i]

    As a result, virtually all retailers and retail suppliers are adapting their operations to manage e-commerce order fulfillment. Many are grappling with the pivotal question of cost-effectively handling online orders’ exponential growth, adapting their existing facilities, and/or designing new operations to manage omnichannel fulfillment efficiently.

    E-Commerce and Traditional Retail Order Management Profile Differences

    The goal should be to use existing distribution center facilities to integrate the e-commerce sales channel efficiently and profitably into the company’s overall order fulfillment operation.

    Blog: Automate an Existing DC or Open a New Satellite Warehouse?

    Yet, adding e-commerce order fulfillment to an existing DC operation can be complex to manage, mainly because e-commerce orders have a markedly different order profile than orders shipped to retailers and B2B operations.

    E-commerce orders typically contain a single or a few individual items. For example, an e-commerce order may include garments of multiple sizes, with the buyer aiming to keep some items and return others. Today, e-commerce order SKU counts are trending lower, with 60% of e-commerce orders consisting of 1 – 3 line items and 15%+ consisting of 1 SKU, a trend that shows no signs of slowing down.

    E-commerce orders are generally small package-sized shipments delivered via parcel carriers such as UPS, FedEx, or the USPS to a consumer at a residential address rather than being shipped to a store or distribution center. These orders are vastly different from less-than-truckload (LTL) mixed-case pallet shipments or full trailers delivered to a distribution center via freight carriers.

    As a result, many operations struggle to blend split-case, low-SKU count orders into operations set up to fulfill predominately full-case, full-pallet LTL orders.

    Without the right processes and technology, managers will be forced to adapt with costly and time-consuming manual workaround processes. The DC operation will struggle to efficiently pick, pack, and ship e-commerce orders alongside the operation’s larger shipments.

    How to Cost-effectively Integrate E-commerce Fulfillment into Your Operations

    Speed and accuracy are critical components of profitable order fulfillment operations. To integrate e-commerce order fulfillment into your existing operations, you will need to devise an efficient, low-touch process that contains costs, ensures accuracy, and meets customer delivery expectations.

    From the moment orders are received to when they are picked, packed, and shipped, the processes must be lean, accurate, result in a low cost per order, and be scalable and adaptable to change. These criteria are particularly true for e-commerce orders with order fill windows measured in a few hours to satisfy customer service expectations that build loyalty. 

    Additional E-commerce Fulfillment Requirements

    Increasingly, wholesalers and other suppliers to retailers must add in-house e-commerce order fulfillment capabilities to their operations to satisfy multiple sets of shipping requirements for numerous channels, including direct-to-consumer, retail clients, Amazon direct-to-customer shipments, and other online marketplaces.

    Fulfilling these orders requires additional pick, pack, and ship rules and processes, as well as the ability for distributors to provide retailer-specific compliance labels, packing documentation, and return labels to each shipment.

    Blog: Key Automation For Omnichannel E-commerce Order Fulfillment Solutions

    One example of this is the fulfillment of orders that appear to the end customer as if the shipment originated directly from Amazon or another specific retailer when, in reality, it is fulfilled by another distribution operation.

    Essentially, the distribution center acts as a 3rd party logistics provider (3PL) that fulfills e-commerce orders for Amazon and its retail customers. The order picking, packing, documentation, and labeling must match each retailer’s specifications to avoid compliance fines that are assessed if the order is shipped with the wrong labels, is missing labels, or has missed delivery windows.

    Technologies that Support Integrated E-commerce and Traditional Fulfillment

    By its very nature, e-commerce is a problematic distribution channel to manage. It is not well suited to manual paper-based or RF-managed pick-and-pack processes that rely on human decisions to enforce shipment rules. A highly efficient pick, pack, and ship process design directed with the right technology can ensure lower labor costs and higher accuracy in order fulfillment.

    Blog: The True Cost of Not Automating Your Warehouse

    The optimal solution to address these complexities is implementing an end-to-end warehouse execution (WES) platform that integrates and automates e-commerce and traditional fulfillment processes. Tier I WES solutions, such as Numina Group’s RDS™ WES solution, offer the flexibility and configurability needed to accommodate specific fulfillment needs.

    RDS includes sophisticated order release planning software and voice-picking technology to optimize, automate, and direct pick and pack rules, ensure order accuracy, track order details, and increase worker productivity.

    Learn More About the RDS WES-WCS Platform

    Numerous other technologies can be integrated to eliminate manual processes, such as automated conveyors, batch-picking modules with AMRs, document print-fold-insertion systems, scan-weigh-dim systems, print-and-apply labeling, and manifesting systems.

    You will achieve the highest performance improvements and ROI by conducting a warehouse engineering and automation design study to determine the right technologies for your operations, ideally deployed with an end-to-end warehouse execution system (WES) such as Numina’s RDS™ platform.

    Learn More

    The best way to ensure that you’ll achieve the desired ROI on your warehouse automation project is to work with an independent systems integrator who is vendor-neutral and has in-depth experience working with all the leading material handling providers. This will ensure that your solution will be based on the best technology that suits your specific operations. 

    You will also achieve the best results by selecting a systems integrator such as the Numina Group, which specializes in warehouse automation and optimization solutions. The Numina Group has over 40 years of experience helping companies optimize warehouse processes to gain space efficiency and reduce labor costs across order fulfillment operations. 

    Contact us

     

     

     

    [i] https://www.shopify.com/blog/global-ecommerce-sales

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