Author: Jen Maloney

  • Stop Manually Packing and Shipping – Discover Pakt™

    Stop Manually Packing and Shipping – Discover Pakt™

    Numina Group Blog

    Stop Manually Packing and Shipping – Discover Pakt™

    January 16, 2023

    Because we eat, sleep, and breathe warehousing, we intimately understand the importance of improving picking productivity and the constraints that exist in the absence of advanced technology.

    However, the lack of attention and viable options for automating packing and shipping has quickly become the point of constraint. 

    Fulfillment is like a triathlon in that it has three events (picking, packing, and shipping) – the key difference being that you are only as fast as your slowest event.

    After automating the picking process, the bottleneck often merely shifts to packing and shipping. This pinch point prevents companies from realizing any building-level throughput improvements achieved by optimizing order picking.

    You’ve Increased Picking Productivity – Where is Your Bottleneck Now?

    The picking productivity increase may solve one direct labor problem, but in doing so, it creates another. You will now have to find space and people for manual pack & ship stations to accommodate your improved picking productivity.

    So where are the packing and shipping automation solutions, and why are they so scarce compared to picking automation solutions?

    Traditionally, warehouse operations seeking automated pack-and-ship functions have had to approach integrators to develop customized solutions that are static and specific to their operations.

    Due to the nature of these customizations, these solutions are overly expensive, have long lead times to implement, are inflexible when it comes to adding capacity or capabilities, and become hard to support.

    Simply stated, pack and ship automation has never been productized.

    Furthermore, the procurement process for pack/ship automation has historically been a maddening process. Legacy integrators have notoriously leaned into complexity as a commercial strategy – creating intricacy for the purpose of selling the ability to navigate through it. Worst yet, if you do not have eight figures to spend, most will not even give you the time of day.

    The fact of the matter is there is still a tremendous amount of non-value-added labor being incurred in both packing and shipping that should be automated out of the operation.

    We have seen a disproportionate amount of warehouse optimization projects solely focused on picking when we know full well that true warehouse optimization only occurs when there is a steady, consistent flow across each of the three functional areas.

    That is why we are launching Pakt™, a fully productized pack and ship automation solution that is purpose-built for fulfillment operations. 

    We aim to demystify pack/ship automation by synthesizing it down to a consumable technology product. Pakt is a post-pick, end-of-line solution comprised of:

    • Scan, Weigh, Vision Audit (SWD): To ensure the right products have been picked into the right shipping container based on weight and to 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 as well as 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.
    • Shipping Sortation: To automatically sort shipping containers based on parcel carriers, LTL, FTL and exceptions

    Pakt Yields a 5X Pack & Ship Productivity Gains and 70% Reduction in Labor Costs 

    The Pakt solution increases pack and ship productivity from, at minimum, 1 order per minute to 10 orders per minute. 

    For every 10 packers/shippers required for a manual process, clients can anticipate a 7-worker reduction.

    Regardless if our clients procure Pakt as a capital investment or as an Automation-as-a-Service (AaaS) investment, we make a pact to deliver a solution that will meet their financial business objectives.

    After decades of designing, implementing, and supporting hundreds of pack/ship solutions, Numina Group is uniquely qualified and positioned to bring this solution to the warehouse automation marketplace.

    Ready to learn more? Contact the Numina Group today. 

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  • Where are the Case-Picking Autonomous Mobile Robots?

    Where are the Case-Picking Autonomous Mobile Robots?

    Numina Group Blog

    Where are the Case-Picking Autonomous Mobile Robots?

    December 7, 2022

    While the warehouse automation world has focused on the rise of e-commerce and “each-picking,” case-picking operations have been left starved for viable robotic automation options.

    The fact remains that, at present, e-commerce still only represents roughly 14.8% of retail sales. Case-picking operations face the same labor crisis as everyone else, and it’s about time for a solution. 

    What is an autonomous mobile robot (AMR)? 

    At Numina Group, we’ve focused exclusively on solving the hardest intralogistics problems for the last 40+ years. When we examined this problem, we identified the top five reasons case-picking autonomous mobile robots (AMRs) options are limited.

    5 Top Reasons Case-Picking AMRs Have Been Limited

     
    • Heavier AMR payloads historically = more expensive, ROI-prohibiting robots.

      As you increase the payload requirements of an autonomous mobile robot, you increase the COGS of the AMR itself. Until present day, higher payload capacity robots have not aligned with the cost justification relative to the average fully burdened wage rate in North America. 

      Rising wage rates and advancements in robotic manufacturing are rapidly closing this cost/benefit gap.  

    • Case-picks are harder to optimize – clustering, batching and sorting require nuance.

      Optimizing case picking is constrained by the size and weight of the physical box. Unlike “each-picking,” it is far harder to grab several units at once or pick multiple orders concurrently.

      Additionally, most slotting strategies for case-picking operations require warehouses to slot items from heaviest to lightest, or lightest to heaviest to avoid crushing product. This materially impacts travel-path reductions from order allocation logic alone, leaving zone-picking as the primary picking methodology.  

      Benefits of Warehouse Slotting & Tips for Optimization

    • Venture capital investments in robotic startups are drawn to ecommerce.

      The rise in e-commerce cannot be ignored. As a percentage of total retail sales, e-commerce has skyrocketed in the last 20 years to roughly 15%. This has attracted significant investment, particularly from the venture capital world in the development of e-commerce-specific automation solutions.

      Amazon started this warehousingspace-race back in 2012 with the acquisition of Kiva Systems, and the intralogistics space has never been the same. However, e-commerce growth has tapered in the last year and B2B still has a long road ahead. 

    • No one is leveraging warehouse voice picking technology to execute the transactions on AMRs.

      There is no shortage of AMR startups who have focused on the development of the robots required to process case picking. Look at the most recent Styleintelligence “AGV & AMR Robotics Report 2022 and you will find dozens of companies with workable hardware solutions.

      What has been missing is the appropriate task execution technology to integrate your human workforce with robotics. By combining a voice picking system (a hardened and reliable warehouse automation technology with superior performance to RF/Paper) with robotics, case-picking AMRs become viable.  

    • Case-picking operations require warehouse execution software (WES) to orchestrate other tasks simultaneously.

      Above and beyond the material movement and the task execution, a high-level or real-time orchestration in case-oriented operations is required. Case-picks, when processed optimally, should be batched, zone-picked and consolidated synchronously.

      While WES has been a commercially available technology for decades, AMR providers have not yet prioritized the development of truly extensible WES capabilities as a function of their technology stack.  

    Finally, a Case-Picking Robotic Solution!

    The Numina Group recognizes the challenges that are outlined above. As warehouse automation experts, it’s our obligation to develop creative, scalable, and hardened products to service underserved markets.

    It is not in our DNA to sit on the sidelines and wait for someone else to develop the appropriate solutions while operations continue to face tougher macroeconomic conditions.  

    If you’re interested in learning more about our case-picking robotic solution, BatchBot, check out the video below then give us a call.  

    Ready to learn more? Contact the Numina Group today. 

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  • What is Slotting in a Warehouse? Benefits & Tips for Optimization

    What is Slotting in a Warehouse? Benefits & Tips for Optimization

    Numina Group Blog

    What is Slotting in a Warehouse? Benefits & Tips for Optimization

    November 8, 2022
    Optimizing Warehouse Slotting is an Easy Way to Reduce Labor Needs

    Automation is the ultimate answer to the question of how to significantly reduce labor requirements and increase productivity in a warehouse operation, which in turn increases profitability.

    Guide to the Basics of Warehouse Automation

    Short of automating your entire warehouse, however, instituting an intelligent slotting system for your products will also increase productivity while reducing the labor hours to move, store and replenish your product and to fulfill your orders on a timely basis.

    What is Slotting in a Warehouse Business?

    Slotting is a process of organizing product inventory to maximize space and efficiency in the warehouse. It is an integral part of the warehouse design process to optimize product flow for maximum picking, packing, and shipping efficiency.

    By reducing travel time, proper slotting increases efficiency for moving, storing, replenishment and picking for order fulfillment. The old adage “time is money” holds true for warehouse cost savings as well. If the storing, replenishment, and picking of goods are more efficient, fewer workers can complete the same amount of work in the same amount of time.

    Step 1: Conduct a Product Usage and Slotting Analysis

    The first step is to perform a product usage and slotting analysis.

    During the design services phase, it is recommended that you have a detailed slotting study performed, especially if your operation is stocking and shipping thousands of SKUs.

    One option is to use slotting software to perform SKU velocity analysis to determine the highest moving SKUs and recommend ideal slotting positions for them in “Golden Zones” along with an ideal A, B, and C velocity storage and picking map.

    This early evaluation will also help establish the right type, ideal size, and quantity of storage racks/shelves.

    The goal is to maximize storage space and minimize replenishment labor. The storage improvements you make, combined with creating an optimized path for picking operators, will shorten travel time anSd reduce labor requirements in picking operations.

    For example, when undertaking such an analysis for our clients, Numina Group conducts a thorough lean analysis with design and time studies, incorporating value stream mapping to drill down into each process, eliminate waste and non-value-added touches.

    This highly visual analysis tool enables us to identify redundancies, gaps, disconnects, and bottlenecks in your system. We conduct in-depth lean analysis of current and proposed distribution processes, analyzing product slotting,  profiling, and SKU velocities.

    What is a Slotting “Golden Zone?”

    The Golden Zone refers to the slotting position that is knee-to-shoulder height range along the shortest pick path to the packing area to eliminate wasteful picker “wander time.” 

    Most distribution operations have an 80/20 or 70/30 product profile in which 20-30% of the total SKUs represent most of the products shipped.

    Proper use of the Golden Zone provides ample opportunities to create huge efficiency gains and profits.

    What are the Benefits of Improved Slotting?

    Improved SKU slotting yields instant efficiency gains. Benefits include picking and replenishment productivity boosts gained or achieved by identifying and grouping products with “like” order shipment profiles together, minimizing travel paths, and improving workplace safety by slotting high movers ergonomically.

    How Often Should Slotting Analysis Be Performed?

    Target your re-slotting audits to occur monthly or, at the very least, quarterly. 

    If you plan to implement an automated warehouse system to streamline picking, packing, and shipping, conduct a product slotting analysis early in the design and engineering process.

    The warehouse design study will also recommend improved practices, including how to manage and regularly perform slotting improvements (not just once a year).

    Target your re-slotting audits to occur monthly or, at the very least, quarterly.

    Learn more about Numina’s Warehouse Design and Engineering Services

    Numina Group provides comprehensive warehouse design and layout services, beginning with a holistic approach that analyzes processes and people. Next, we determine the technologies that provide the maximum profitability and the fastest return on investment (ROI). 

    Our experience and expertise in warehouse design sets us apart from the competition. We provide massive labor reduction and cost savings through the combination of automation and lean design.

    Numina Group will optimize order flow throughout your entire operation, providing an immediate ROI. Our in-depth warehouse design solutions include:

    • Design and time studies
    • Product slotting and profiling
    • SKU velocity
    • Footprint requirements
    • Blueprint of optimized design for maximum profitability
    • Technology selection
    • Return-on-investment (ROI) analysis
    • Guaranteed performance

    By identifying these areas through data analysis in a visual approach, we can make strategic decisions together to eliminate waste and provide value in all aspects of your automated warehouse system.

    Our warehouse design and layout services have helped clients double and even triple their productivity per employee. Typical productivity gains of 35% to 50% have been achieved hundreds of times across a plethora of industries including: omni-channel, e-commerce, consumer goods, healthcare, pharmaceuticals, electronics, third-party logistics (3PL) and many more.

    The Numina Group has designed and implemented over 1,000 warehouse automation projects in diverse warehouse environments across North America.

    We offer one of the industry’s most advanced engineering teams with deep experience in testing, evaluating, and installing various software and material handling technologies.

    Let us put our extensive industry-focused knowledge to work for you.

    Ready to learn more? Contact the Numina Group today. 

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  • The ROI of Voice Picking

    The ROI of Voice Picking

    Numina Group Blog

    The ROI of Voice Picking

    November 8, 2022

    How to Quantify the Cost-Saving Benefits of Voice Picking Technology

    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 a proven method to reduce manual picking tasks, lower labor costs, and increase profitability.

    What is Voice Picking Technology?

    A pick-by-voice solution directs the operator’s movement using voice commands combined with product barcode scan validation to direct a more efficient picking process in a fast, consistent manner with built-in order pick & pack validation.

    Today’s most advanced voice-picking solutions combine the convenience of voice-directed instruction, wireless headsets, and hands-free barcode scanners for fast, paperless order picking and task validation.

    When configured for optimal efficiency, voice-picking takes the guesswork out and enforces uniform best-practice work procedures across the order fulfillment process.

    Expected ROI Gains 

    The ROI achieved with voice picking varies by company, as every warehouse has unique requirements. However, in averaging the ROI across diverse operations, first-generation voice-picking technology yields a 25% to 35% improvement in productivity.

    The ROI can be 50% or higher when voice picking is integrated with a real-time order fulfillment suite similar to Numina Group’s Victory Voice Suite, to replace a paper-based discrete order picking system.

    A voice-directed order fulfillment solution should yield an ROI in as little as 12 to 14 months for a company with predominantly manual discreet paper-based picking operations.

    Voice-Directed Picking Productivity Gains

    Latest generation voice picking solutions, such as Numina Group’s Victory Voice™ Suite, are voice independent, easy to learn, and require zero operator training. New employees and seasonal staff can be productive in 15 minutes or less.

    Victory Voice is the latest advancement in multimodal order picking, yielding 99.9% picking accuracy and reducing pick and pack labor requirements by 50% or more in existing operations. Several clients have increased picking rates to 230-300 lines per hour in high-velocity, properly SKU-slotted pick zones.

    The best voice-picking solutions are capable of handling diverse picking requirements. For example, Victory Voice is highly flexible and supports multiple picking operations, including:

    • Pick to conveyor
    • Discrete orders
    • Batch cart picking
    • Mixed case pallet
    • Full pallet pick
    • Directing multi-zone consolidation for LTL and truck shipments

    To achieve the greatest ROI, choose a voice-picking solution that includes order fulfillment optimization components to further enhance efficiency and accuracy.

    For example, Victory Voice includes an optimized order release module that supports continuous and batch order release planning, models the most efficient employee pick paths, synchronizes workers’ tasks with mobile warehouse robots, and includes built-in, advanced cartonization software to ensure least-cost shipping.

    Learn more about the RDS Victory Voice Suite

    Getting Started

    Before you select a voice-picking solution, it is essential to gather data and perform an analysis to determine the technology for your operation. Questions to consider include: 

    • Are you still relying on paper in the picking and order fulfillment operation?
    • Do you mainly rely on a discrete, one-at-a-time order-picking process
    • Do you pick and pack to a single carton? Spoiler alert: order release software and cartonization software logic will remove all unnecessary steps out of picking and packing.
    • Is picking and packing a bottleneck that restricts throughput during daily peak periods and peak season shipments?
    • What is the daily labor requirement to perform packing and QC order checking
    • What are your yearly labor costs for order picking and secondary QC?

    To ensure that your project achieves a measurable and rapid ROI, work with an independent warehouse system integrator to benchmark your existing operations and conduct a warehouse engineering study that forms the basis of your warehouse automation solution.

    Learn More About Numina’s System Integration Services

    As a leading warehouse software developer and independent systems integrator with more than three decades of experience, the Numina Group can help you navigate the complexities of choosing the right technologies with our turnkey warehouse automation software and hardware services.

    Ready to learn more? Contact the Numina Group today. 

    We’re excited to invite you to join us at Modex 2022 Booth #B1813 to discover how we blend pick, pack, and ship automation that together drives the greatest gains in DC profitability. 

    Learn More:

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  • The Basics of Warehouse Automation

    The Basics of Warehouse Automation

    The Basics of Warehouse Automation

    Jen Maloney
    November 1, 2022

    The Goal of Warehouse Optimization

    The goal of warehouse optimization is to increase efficiency and profitability by deploying lean processes. This is achieved with warehouse automation and warehouse control and execution software creating fast, continuous order flow across the entire pick, pack, and ship fulfillment operation.

    A Design-First Approach

    The first step for a successful integration meeting all project milestones is to start with a design-first approach

    The best practice is to engage a warehouse system integrator to work closely with your internal team.

    The process begins with the warehouse automation systems integrator and in-house team focusing on a business-first approach to align labor, technology, and operations with business strategy and corporate vision. 

    The implementation of warehouse automation requires an experienced electrical, mechanical, and industrial engineering team and advanced software capabilities on hand.

    Benchmark Your Existing Warehouse Operations

    To develop a warehouse optimization plan, your team and the integrator work together to benchmark existing operations, identify areas of process improvement, and recommend warehouse automation technologies to support the optimization goals.

    Learn More About Numina’s Warehouse Optimization Design Services

    The outcome of this process is a plan or roadmap that provides business managers with the vision and justifications for making operational changes. To ensure the project meets the company’s order fulfillment requirements, three factors need to be evaluated and aligned – workforce, workplace, and the performance of the work.

    A Data-Driven Roadmap for a Successful Optimization Project

    • The engineering plan and subsequent optimization plan are data-driven. At a minimum, it should be based on a year or more of past order data, including detailed data on order profiles, shipment sizes, and the current workflow of your picking, packing, and shipping processes.  

    Order and SKU movement data analysis is reviewed to understand and recommend improvements to product storage and to ensure that:

    • Items are stored in the optimal locations to streamline picking
    • Correct storage technology is used, and
    • Optimum travel paths are achieved for the most efficient order flow across the operation

    Warehouse Engineering Study Results

    The outcome of the engineering study is a benchmark of current performance, recommended process improvements, identification of the right technologies matched to the order profile, and the elimination of extra touches and bottlenecks.

    It should project a future 3-to-5 year period for growth, factoring in order profiles, SKU movement velocity, peak periods, and how future growth will impact facility capacity.

    What is Warehouse Slotting? Tips & Benefits for Optimization

    Once the study is complete, the data essentially becomes a single version of the truth by which all processes and technologies can be evaluated, contrasted, and selected to improve an existing operation or design a new DC.

    Warehouse Automation Technology Review

    Once the engineering plan is complete and signed off on by both teams, you can begin reviewing warehouse automation technologies to identify those that will optimally increase the order flow across the pick, pack, and ship operation.

    Voice-picking technology, mobile warehouse robots, order release planning software, cartonization logic, scan-weigh-dim, and print-and-apply technology are some of the warehouse technologies to consider, along with process improvements to increase picking rates.

    Learn More About Numina’s Warehouse Automation Solutions

    The Role of Warehouse Automation Integrators

    The systems integrator’s role is to help you create the best possible optimization plan for your specific operations. Their role is also to ensure that you choose the ideal technology for your unique order fulfillment needs, as there is no “one-size-fits-all” solution.

    Work with an independent warehouse automation integrator who is a true subject matter expert (SME) and can bring application expertise, knowledge, and operational experience to identify and implement improvements.

    An independent systems integration expert can provide an unbiased evaluation of all your technology options for your warehouse operations and business goals.

    Learn More About Numina’s System Integration Services

    If you have questions about optimizing your warehouse, the Numina Group offers expert warehouse design, implementation, integration, and consulting services.

    Ready to learn more? Contact the Numina Group today. 

    We’re excited to invite you to join us at Modex 2022 Booth #B1813 to discover how we blend pick, pack, and ship automation that together drives the greatest gains in DC profitability. 

  • Order Picking Automation Options to Resolve Warehouse Labor Shortage Challenges

    Order Picking Automation Options to Resolve Warehouse Labor Shortage Challenges

    Order Picking Automation Options to Resolve Warehouse Labor Shortage Challenges

    Jen Maloney
    October 22, 2022
    The Right Blend of Picking Technologies Reduces Labor, Increases Accuracy and Productivity Across the Entire Order Fulfillment Operation

    Industry statistics show up to 50% of a distribution center’s labor resources are devoted to picking. The key to optimizing your warehouse operations and labor requirements is to reduce non-value-tasks such as reading, data entry and wasted walking and fork truck travel. 

    The latest generation of picking technologies are only as good as the real-time warehouse execution and control systems (WES-WCS) directing them. 

    With an abundance of choices, it is critical to evaluate processes matched to the warehouse’s operational needs, define the solution, and then select the right blend of software and technologies matched to your business needs and goals that will generate a compelling ROI.

    Here is a short overview of order picking technologies to consider.

    I. A Warehouse Pick-by-Voice System Cuts Labor & Improves Productivity

    A pick-by-voice solution is a lean and simple solution requiring only 15 minutes of operator training.

    It directs a worker’s movements by using voice commands and product barcode scanning for fast, consistent picking.

    Pick-by-voice combines pick & pack validation into the first operator touch, eliminating secondary inspection and packing labor.

    With an intelligent warehouse execution and control system (WCS-WES) managing the voice picking application pick path is automatically optimized, while the voice application ensures accuracy by directing operators to scan validate the location and item barcode with a voice message.

    The best voice picking system takes the worker decisions out by enforcing uniform best practice work procedures throughout both the pick and pack process!

    The latest voice picking software solutions are completely speaker-independent, support multiple languages and require minimal training and management mentoring time.

    Employees significantly prefer working in DCs with voice picking technology compared to working in operations with paper-based or RF terminal picking processes. Higher employee satisfaction equates to better employee retention.

    Multi-Modal Voice Picking

    To achieve the highest productivity levels, voice picking should only be deployed in what is called a multimodal picking technology – a hands-free, eyes-focused picking technology.

    A multimodal picking solution combines voice commands with hands-free camera-based barcode scan validation and a wearable wrist mount display to show the item number and quantity to pick with an image of the product.

    Wearable computers with message displays and touch screen buttons to handle task changes and exception conditions add efficiency to the warehouse workers. Higher accuracy and quality are built into the process by showing the item and quantity to pick, resulting in an easy to learn system.

    Our partner, Zebra Technologies, offers a line of rugged mobile computers that fully support multimodal picking.

    Numina Group’s Victory Voice™ Suite offers the latest neural network voice recognizer for true “multimodal” order picking, yielding 99.9% picking accuracy and reducing pick and pack labor requirements by 50% or more in existing operations. It’s order release module includes order cartonization logic that combines pick and pack into a single step by directing picking into the right size shipping carton. Not only does this reduce packing labor but lowers packaging and parcel shipping costs by reducing the size and quantity of cartons used to fulfill orders!

    Victory Voice offers a suite of software application modules that removes labor across each component of warehouse pick, pack, and ship operations.

    Several clients have increased picking rates to 180 – 300 lines per hour in high velocity, properly SKU-slotted pick zones.

    Voice picking is increasingly being combined with the latest generation robotic goods-to-person (G2P) picking and storage systems and AMR-based batch cart picking to obtain the highest picking productivity across all warehouse picking zones.

    II. Goods-to-Person (G2P) Order Fulfillment Automation

    Goods-to-person order fulfillment defines a broad array of systems used to automate the storage and retrieval of a product.

    With this order picking method, warehouse automation technology moves, stores, and delivers products to the picker, eliminating walking and movement and increasing picking productivity to produce 250 to 350 picks per person.

    Less walking along with ergonomic presentation of the goods achieves the industry’s highest picking productivity rates. In simple terms, products are automatically brought directly to the picker in order pick sequence, who then picks what is needed to fulfill customer orders.

    An investment in a robotic goods-to-person system can increase picking speeds to offset labor costs and enable better utilization of facility space. Goods-to-person functionality can rapidly expand to meet these needs, making warehouse robotics more cost-effective.

    III. Which G2P System is Best for Your Operation?

    Choosing the right blend of picking technology is a complex decision with hundreds of warehouse robotic technologies to choose from. The first question is whether your order profile is a good fit for a G2P system?

    Next, analyze the pros and cons of the various G2P systems, especially the increased performance and cost effectiveness of the latest generation of robotic goods to person technologies to assess which is the best solution for your mix of products, picking, and storage needs.

    To ensure your business receives the full benefit of the G2P system, partner with an independent systems integrator to evaluate your operation and ensure that a G2P system is right for your operation.

    It takes a knowledgeable partner and a design-first approach to analyze your mix of SKU sizes and velocity movement and determine which G2P Solution is best suited for your specific operations.

    IV. Batch Picking with a Batch Cart, AMR, or Fork-Truck

    Time is money and wasted travel time is one of the largest drains on warehouse profitability. 

    You can reduce this costly problem by deploying an intelligent batch picking process, guided by technology, to select and execute order release and assignment based on the shortest travel path for a batch picking cart, mobile robot, or fork truck.

    The process is controlled and directed by a WES-WCS transport path travel execution module that directs the batch cart, fork truck, or autonomous mobile robot (AMR) pick path to each pick location in sequence order.

    If the warehouse is using AMRs, pickers are simultaneously directed in each aisle pick zone to meet the AMR and perform voice-directed picks to carton, as well as sweep single line order items to a tote using a speed pick process.

    Batch order selection includes like-SKU order pick logic that reduces picker visits to the same location to increase line quantity picking during a storage bin visit and allows batch cart picking across a dozen or more orders simultaneously, resulting in over a 100% picking productivity gain compared to a discrete order picking process.

    An independent systems integrator can define and design your warehouse future roadmap.

    Create Your Future Roadmap to Warehouse Automation Success

    If you are considering an automated warehouse system solution, our short Warehouse Automation Checklist can help you evaluate your current operation.

    Download the Warehouse Automation Preparation Checklist

    Numina Group is an independent software development and warehouse automation system integrator. We partner with your team to design and implement warehouse automation solutions. We review, compare and select the right blend of picking, packing, and shipping technologies to create an optimized warehouse automation solution for your entire order fulfillment operation.

    We can help you choose the right blend of automation to increase productivity and scale your business, such as RDS™ warehouse automation software, voice picking technology, mobile warehouse robots, pick-to-light, put-to-light, goods-to-person (G2P) solutions, scan-weigh-dim automation, and print-and-apply labeling.

    Our warehouse automation solutions are modular and scalable, and enable you to realize benefits that drive a rapid ROI. 

    Ready to learn more? Contact the Numina Group today. 

    We’re excited to invite you to join us at Modex 2022 Booth #B1813 to discover how we blend pick, pack, and ship automation that together drives the greatest gains in DC profitability. 

  • Seven Steps to Prepare for the New World of Peak Season Shipping

    Seven Steps to Prepare for the New World of Peak Season Shipping

    Seven Steps to Prepare for the New World of Peak Season Shipping

    Jen Maloney
    September 22, 2022
    Peak Season Tips

    First, the good news – holiday retail sales are likely to increase between 4% and 6% in 2022, and e-commerce sales will grow by 12.8% to 14.3%, year-over-year, during the 2022-2023 holiday season, according to Deloitte.

    Next, the challenging news – post-Covid, consumer buying habits have changed considerably, requiring retailers to rethink their peak season strategies.

    Many shoppers are back to in-store browsing, while a large percentage of buyers continue to order online for home delivery or click-and-collect. Demands for flexible delivery options, such as BOPIS (buy online, pick up in store) continue to grow.

    Also, due to high inflation, consumers are planning to shop earlier than usual as a ploy to avoid higher prices. The concept of the single-day Black Friday has morphed into the week of Black Friday (or more).

    As a result of these trends, retailers will be shipping higher volumes for both home delivery and store fulfillment. Multiple sales channels or omnichannel refers to a distribution operation that has multiple channels to fulfill, such as direct-to-consumer e-commerce, fulfillment to their own branded stores, and fulfillment to major retail or specialty stores. 

    These changing dynamics point to the need for ample preparation and efficient picking, packing, and shipping processes to fulfill orders for multiple sales channels.

    Equally important, the notion of a single peak season has given way to many peak seasons, and retailers must adapt fulfillment strategies to meet dynamically changing customer demands.

    Seven Steps to Take to Prepare for Your Next Peak Season

    To gain maximum efficiency, it’s wise to consider a warehouse automation system.

    However, for this year’s holiday season, it’s too late to select and implement  system. 

    There are, however, other immediate steps you can take now to ensure your procedures are as efficient as possible, and apply to all warehouse environments.

    I. Evaluate Your Slotting Processes

    It’s not feasible to redesign your entire warehouse layout just before peak season, but it is feasible to analyze and improve product movement through your warehouse.

    Your slotting strategy should make the order picking process more efficient and accurate.

    As a first step, evaluate your slotting process for your company’s entire SKU mix. Identify the low, medium, and high moving products and make sure the highest movers are stored in the most optimal locations to speed up order picking – with easy accessibility at the storage location and in their placement on a shelf or rack.

    Products should be slotted according to a strategy that reduces workers’ travel time during picking and reduces the number of touches required by workers to fulfill orders.

    You may also consider implementing a batch-picking strategy to increase efficiency and productivity. In this scenario, workers pick multiple orders (batches) simultaneously rather than filling one order at a time. Batch picking works well when a few very popular SKUs comprise a large percentage of the orders.

    Learn more about Numina’s Batch Picking Solution  

    Remember that any changes made to improve throughput must also ensure accuracy. Shipping the wrong item, especially during the peak holiday season, is a sure way to lose a repeat customer. If you implement a new picking strategy, you will need software that manages orders, inventory, and pickers to handle the new process.

    Other questions to ask:

    • Do you adjust product stock to accommodate peak season inventory management?
    • Will the item be picked individually or as a full pallet?
    II. Lean Up Packing Operations

    If you can eliminate the pack operator’s task of manually building cartons, you’re eliminating 20 to 30 seconds from every carton shipment. One way to achieve this is to pre-make and stage the most predominantly used shipping carton sizes at the packing stations or pack lines.

    III. Limit Congestion

    Higher peak season sales levels result in a higher volume of products being stored on the floor, which can cause congestion and impede workflow areas. To avoid this, implement a plan of more frequent replenishment in smaller quantities to keep the aisles unobstructed.

    It’s also essential to have clear signage to direct pickers to different areas, especially if you hire temporary workers who are new to your warehouse layout.

    IV. Calculate Your Staffing Needs

    If you rely on temporary or seasonal staff to cover increased demand over the holidays, begin recruiting and hiring efforts early enough to allow sufficient time for new employee training before peak season begins.

    Doing so ensures that your best workers are available to process orders when they’re needed most and not sidelined with training requirements or directing temporary workers’ tasks.

    V. Update Staff Training Requirements and Procedures

    It is crucial to have staff training needs and processes defined and finalized and to test new training initiatives before the stress and confusion of peak season hits. 

    Hint for the future – today’s newest voice-directed order picking solutions, such as Numina’s Victory Voice™ Picking Suite, remove the challenges of training and onboarding seasonal staff while ensuring fast, accurate picking performance. 

    The Victory Voice picking system uses deep learning neural networks with AI recognition to deliver best-in-class speaker-independent natural language recognition.

    Voice-directed picking, combined with wearable mobile computers for scanning and validation, enables workers to work hands and eyes free – a much faster approach.

    As a result, Victory Voice requires zero voice training and does not capture or record the operator’s voice biometrics. It’s easy and intuitive, so temporary or new operators are trained and productive in as little as 15 minutes!

    VI. Conduct Preventive Systems Maintenance and Audit Your Spare Parts Inventory

    While unexpected downtime on an essential piece of equipment is never good, it can be a much more costly headache during peak season.

    That’s why it’s critical to audit your systems’ readiness ahead of time and ensure that equipment can perform under increased stress from the holidays.

    Now is the time to plan for the unexpected. 

    • Practice preventative maintenance for all warehouse automation and material handling systems.
    • Verify that all your support agreements are active and up to date.
    • Make sure you have spare parts on hand for all your equipment and stock up on the spare parts with the greatest potential to break down.

    These steps will help ensure that your people and technologies are able to continue to perform with higher throughputs and demand during peak.

    VII. Plan for the Future

    Once the peak season is over, start planning for next year. Consider the major challenges you faced during the peak season that you need to prevent going forward and make a plan to improve missteps.

    The best approach is to audit your current picking, packing and shipping operations to identify the bottlenecks, improve your fulfillment processes and ensure that your workflow is based on an effective warehouse design.

    Learn More About Numina’s Warehouse Design Engineering Services

    As you begin to explore your options, here are some key data points to capture:

    • How many cartons/padded bags were shipped during peak season
    • Number of pickers during an average shift compared to peak season
    • Number of shifts on average compared to number of shifts during peak season?
    • What is the average order cycle time during peak
    • What was the highest number of customer complaints? Accuracy, missed delivery dates, etc.?

    If you are considering an automated warehouse system solution, the Numina Group has created a short checklist to help you evaluate your current operation to determine the best solution for your unique operation.

    Download the Warehouse Automation Preparation Checklist

    Once you’ve completed the operational audit, you’re in an excellent position to identify the right warehouse automation solution to optimize your operations. Integrating automation and process improvements is the best way to eliminate inaccuracies, reduce labor costs, and remove dependence on temporary workers. Not only will it enable your company to create a more efficient distribution process that scales up for peak-season shipping, but it will also pay dividends throughout the year.

    Numina Group can help you choose the right blend of automation to increase productivity and scale your business, such as RDS™ warehouse automation software, voice picking technology, mobile warehouse robots, pick-to-light, put-to-light, goods-to-person (G2P) solutions, scan-weigh-dim automation, and print-and-apply labeling.

    Our order fulfillment automation solutions are modular and scalable, allowing you to focus on the right blend of automation technology to realize benefits that drive a rapid ROI. 

    We have over three decades of experience as system integrators, designing and implementing automation in new and existing distribution centers.

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

    Ready to learn more? Contact the Numina Group today. 

    We’re excited to invite you to join us at Modex 2022 Booth #B1813 to discover how we blend pick, pack, and ship automation that together drives the greatest gains in DC profitability. 

  • Improve Picking Productivity and Reduce Labor Costs with Victory Voice Picking Technology

    Improve Picking Productivity and Reduce Labor Costs with Victory Voice Picking Technology

    Improve Picking Productivity and Reduce Labor Costs with Victory Voice Picking Technology

    Jen Maloney
    August 16, 2022

    Warehouse order picking operations can consume 50% or more of a distribution center’s labor spend when accounting for order picking, quality control, and packing activities.

    For this reason, one of the most crucial warehouse improvements a company can make to gain higher business profitability by improving picking productivity and accuracy is to invest in warehouse automation.

    Every warehouse has unique requirements, which is why it is essential to gather data and perform a warehouse engineering study to first determine the right blend of technology for your operation. Equipping your workforce with voice-picking mobile wireless wearable computers, blue-tooth wireless hands-free barcode scanners, and a headset is a leading candidate for most applications.

    What is Pick-by-Voice?

    A pick-by-voice solution directs the operator’s movement using voice commands combined with product barcode scan validation to direct a more efficient picking process in a fast, consistent manner with built-in order pick & pack validation.

    Pick by voice is a lean and simple solution that requires only 15 minutes of operator training. It automatically enforces an optimized pick path to the correct location, and scan validates the location and item barcode with a voice message.

    If your are currently relying on paper-based picking or using handheld terminals that require operators to key in data for picking or other warehouse work tasks, it’s time to invest in picking technology that is proven to significantly boost accuracy and productivity.

    Voice Picking

    Wearable computers with message display efficiently provide warehouse workers with the item and quantity to pick, resulting in an efficient, hands-free, eyes-focused picking operation.

    Take a quick look at your operation, and answer these simple questions:
    • Are you still relying on paper in the picking and order fulfillment operation?
    • Do you mainly rely on a discrete, one-at-a-time order picking process?
    • Do you pick and pack to a single carton? Spoiler alert: order release optimization software and cartonization software logic will remove all unnecessary steps out of picking and packing.
    • Is picking and packing a bottleneck that restricts throughput during daily peak periods and peak season shipments?
    • What is the daily labor requirement to perform packing and QC order checking?

    A Warehouse Voice Picking System Improves Productivity

    Voice picking system performance rates can provide gains of 80+ lines picked per hour compared to RF-directed picking. Victory Voice™ Picking, the latest technology released by Numina Group, combines voice commands with “hands-free camera” based barcode scan validation and a wearable wrist mount display of the item number and quantity to pick with an image of the product.

    Victory Voice is the latest advancement in “multimodal” order picking, yielding 99.9% picking accuracy and lowering pick and pack labor requirements by 50% or more in existing operations.

    Several clients have increased picking rates to 230-300 lines per hour in high velocity, properly SKU-slotted pick zones.

    Victory Voice™ Picking Suite Reduces Warehouse Labor Costs

    Victory Voice PickingThe Victory Voice picking software suite is a component of several best practice modules in Numina’s RDS™ Warehouse Execution and Control Software, WES-WCS platform, Real-time Distribution Software. RDS directs lean, paperless picking, packing, shipping, and other warehouse tasks to reduce labor while increasing order throughput and accuracy.

    Victory Voice automates many basic ERP and warehouse picking and order fulfillment processes. Its suite of automation modules and technologies automates and enforces uniform and efficient workflows across the entire order fulfillment operation.

    Victory Voice is more than just a voice picking application – it is an entire suite of software application modules that removes labor across each component of warehouse pick, pack, and ship operations.

    Order Release

     

    The Victory Voice software suite includes an optimized order release module that supports continuous and batch order release planning and works seamlessly with built-in, advanced cartonization logic.

    The order release module includes efficient order picking practices and automates delivery prioritization rules based on carrier cut-off times and customer-specific client business rules to ensure both parcel and LTL orders are picked, packed, and shipped to the required service levels.

    How Cartonization Software Works with Voice

    Orders are first cartonized to the right size and quantity of shipping containers and released for picking. Less-than-case items and full cases are picked and labeled using one of the Victory Voice Picking Suite’s several pre-developed optimized picking processes.

    The cartonization function uses several cubing algorithms for each SKU’s size and weight to perform simulated packing of each order before selecting the right-sized carton.

    This up-front cartonization feature then takes advantage of the strength of voice picking and hands-free barcode scan validation to direct the picking operator to pick and pack items in a single-touch operation.

    The cartonization software not only calculates the right-sized carton or polybag to use for an order, but voice-directed picking with scan validation ensures both the item pick and placement of the product to the shipping container. It directs the pick operator to scan the carton, tote, or polybag barcode identifier to complete the item pick and put transaction.

    The best voice picking system takes the guesswork out and enforces uniform best practice work procedures across the picking and packing process!

    Smart Batch Cart, AMR, and Fork-Truck Picking

    The batch picking process selects and executes order release and assignment to the cart based on the shortest travel path for both carts and fork trucks. RDS includes a transport path travel execution module that directs a batch cart, fork truck, or autonomous mobile robot (AMR) pick path to each pick location in sequence order.

    At the same time, the pickers are simultaneously directed in each aisle pick zone to meet the AMR and perform voice-directed picks to carton, as well as sweep single line order items to a tote using Victory Voice’s speed pick process.

    Batch order selection includes like-SKU order pick logic that further reduces picker visits to the same location to increase line quantity picking during a storage bin visit.

    The use of multi-parameter optimization logic allows smart batch cart picking across a dozen or more orders simultaneously, resulting in over a 100% picking productivity gain compared to a discrete order picking process.

    Order Release Optimization & Smart Batch Picking to Save Labor

    Time is money, and wasted walk or fork truck travel time is one of the largest drains on warehouse profitability. Victory Voice, as mentioned earlier, is designed to reduce inefficient travel time and labor usage in picking, replenishment, pallet building, and sorting operations.

    Hands-free barcode scanning eliminates wasted time reading check digits.

    Hands-free barcode scanning verifies storage location and item, lot, and serial number capture in a far more efficient manner than traditional pick-to-voice solutions that require reading check digits to confirm picking. Hands-free barcode scanning increases accuracy performance to 99.9% or higher.

    Accuracy is a key component of ensuring customer satisfaction and retention.

    An order fulfillment error can conservatively cost a business $250 per incident, considering the total costs of customer service, accounting, warehouse re-picking, packaging, item replacement, shipping, and inventory adjustments. The cost can be 2X to 3X higher in industries such as medical instruments and products, nutraceutical, pharmaceutical, healthcare, and food lot, and sell-by-date distribution operations.

    A few errors a day put your operation at risk of damaging the customer experience! A single error can result in the loss of a customer. E-commerce and broken case B2B item picking orders have the highest potential for picking and packing errors. Closing the pick & pack validation loop using the highest accuracy picking technology available, pick by voice, eliminates sources of errors crucial for your business success.

    How does a voice picking system + cartonization software reduce labor and shipping costs?

    In an order picking application lacking sophisticated cartonization logic, the warehouse is forced to pick to totes. More labor is spent in these operations where packing operators guess at the right-sized carton and perform additional touches to manually construct, tape, and re-pack items from the totes to cartons and polybags. Cartonization software can decrease the sizes of cartons used to the most efficient, cost-saving size.

    Smaller carton sizes lower shipping costs in a 1,000 carton/day operation by $100,000 a year or more.

    Labor Management and Order History Tracking

    Victory Voice includes key performance indicators for tracking, including operator productivity rates and accuracy by work task and picking performance in each zone. A labor tracking management tool helps identify zones requiring re-slotting, employees needing further coaching, or employees that are due to receive recognition for a job well done!

    As a component of the order fulfillment automation, a labor management and reporting system adds an additional 5% to warehouse productivity.

    How does productivity tracking save labor costs?

     

    Reduced voice picking training time saves labor costs and eliminates training and mentoring time for team leaders, supervisors, and other staff responsible for training the new employees.

    Higher employee satisfaction equates to better employee retention. The Victory Voice picking system is quick to learn and easy to use and reduces employee voice picking training time to 15 minutes or less. Operators significantly prefer working in distribution centers with voice picking technology compared to paper-based or RF terminal picking.

    A voice picking system is ideally suited to direct picking in slow-moving SKU storage areas, high-velocity storage zone routing conveyor pick modules, goods-to-person picking, and storage systems, or batch cart picking. 

    Regardless of the picking process, the latest generation of voice-directed pick-pack-ship order fulfillment automation is one of the fastest ROI technologies proven to lower labor costs, improve accuracy and increase throughput in existing and new distribution centers.

    Ready to learn more? Contact the Numina Group today. 

    We’re excited to invite you to join us at Modex 2022 Booth #B1813 to discover how we blend pick, pack, and ship automation that together drives the greatest gains in DC profitability. 

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

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

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

    Jen Maloney
    August 10, 2022

    The latest goods-to-person (G2P) warehouse robot solutions for order fulfillment have advanced rapidly over the last few years. Today’s G2P robotic solutions are now approaching the performance level of traditional shuttle systems and exceeding the performance of mini-load crane-based storage systems.

    Today’s G2P robotic automation solutions are also less costly than traditional systems. The original generations of tote and case-based shuttle systems and mini-load storage and picking systems are more expensive as precision steel, international shipping, and installation costs continue to rise. These costs increase capital investments and extend the return on investment (ROI) to five or more years.

    Further, traditional shuttle systems based on rail and fixed aisle order picking shuttle carts storage systems deliver fast performance but suffer from a higher cost per storage position and lack the flexibility and scalability of today’s G2P robotic picking solutions.

    While traditional goods-to-person solutions come with higher equipment and installation costs and longer delivery and commissioning time, the latest G2P warehouse robotic solutions overcome these limitations and are more cost-effective. As a result, a growing number of companies are choosing to invest in robotics.

    Latest AMR-based G2P Robotic Solutions Rival Performance of Traditional Shuttle Systems

    The performance advancements and cost savings offered by the latest autonomous mobile warehouse robot (AMR) based G2P solutions are achieved through the innovation of using two or more different task-oriented robots within the same G2P system.

    This is essentially a “divide and conquer” design approach within the next generation of G2P robotic automation. 

    Today’s warehouse robots utilize a much more adaptive and cost-effective means to store and pick products. 

    The latest generation hybrid G2P systems with mobile warehouse robots travel at higher speeds, handle more weight, and reach higher, denser storage shelves than the robotic G2P systems from just a few years ago.

    Lower Investment Cost than Traditional Tote Shuttle Systems

    A major warehouse robotics innovation in shuttle design provides a high-performance, high-density G2P solution that rivals the performance of a traditional tote shuttle system without the high infrastructure investment and costly expansion costs.

    The box and tote-carrying warehouse robots use a modular, scalable design. Teams of different types of robots work together to more cost-effectively store, pick orders, and move products faster and more efficiently while increasing a DC’s facility space utilization.

    Combined Families of Robots to Increase Order Picking Throughput

    These solutions combine two families of robots, the high-reach box and tote carrying and moving robots that can reach heights of 8 meters/26 feet for automatically storing and picking totes and cases.

    These robots include a depth camera and other sensors and use QR code-based navigation to move throughout the order picking and storage aisles.

    The G2P robots can autonomously pick and transfer up to eight totes to floor pick-up locations to move to the picking station. In addition, the bots handle large capacity tote weights up to 85 lbs in dense double deep racking.

    The secret to the boost in performance is using the second family of small and nimble tote-carrying mobile robots teamed with the high-reach picking and storage bots.

    The small shuttle bots travel in separate pick-up and delivery aisles from the high-reach picking and storage bots at the bottom level, inside the four tote or box storage racking.

    When the high reach bot completes the picking of a group of totes and boxes, it moves and inserts the tote into a floor-level pick-up position. This action triggers a message to dispatch the small shuttle bots to travel to the picking location, pick up, and move the tote to the required picking station.

    The same process moves totes from the receiving replenishment area to the required storage aisles.

    Faster Delivery of Totes to Operator Pick Stations

    The dedicated purpose-built tote-carrying bots increase the speed that totes can be moved to the operator pick stations, resulting in tote delivery rates of 300-400 totes an hour within the robotic G2P solutions. 

    The faster pick rates and higher storage density capacity combine to provide a return-on-investment (ROI) of 24 to 30 months, half the time of a traditional tote shuttle storage and picking solution.

    Inherent Redundancy, Reduced Maintenance Costs

    Additionally, robotics-based G2P solutions have inherent redundancy due to no single point of failure and do not require a full-time skilled on-site maintenance staff to operate. The simplified maintenance reduces high yearly operating costs, making these G2P solutions an affordable investment for small to mid-sized warehouse operations.

    G2P and AMR-based picking and storage solutions combined with the right blend of traditional conveyor systems and pack-and-ship automation reduce touches and increase order flow across the entire order fulfillment operation.

    Create Your Warehouse Design Plan Before Selecting Warehouse Automation Technology

    Any business embarking on any automation initiative, especially a goods-to-person or an AMR-based picking solution, needs a warehouse design-first approach to analyze, select and justify the right mix of technologies. 

    This approach needs to happen in partnership with an independent warehouse automation integrator that evaluates technologies and recommends the right blend of technologies to provide a solution with the greatest efficiencies.

    Warehouse Execution & Control Software to Ensure Optimal Performance

    The entire warehouse pick, pack, and ship system performs at the highest level when orchestrated by a top-tier warehouse execution and control system (WCS-WES) software platform.

    Numina Group’s warehouse execution and control software,  RDS™ Real-Time Distribution Software, manages and optimizes order release for G2P and the other warehouse automation technologies that increase productivity, lower manual labor dependency, and generate a rapid ROI.

    Ready to learn more? Contact the Numina Group today. 

    We’re excited to invite you to join us at Modex 2022 Booth #B1813 to discover how we blend pick, pack, and ship automation that together drives the greatest gains in DC profitability. 

  • Goods to Person Solutions for DCs of all Sizes

    Goods to Person Solutions for DCs of all Sizes

    Goods to Person Solutions for DCs of all Sizes

    Jen Maloney
    July 12, 2022

    A decade after Amazon created headlines when it purchased Kiva Robotics, autonomous mobile robots and goods-to-person (G2P) solutions are being widely implemented due to their ability to help companies manage their labor shortage challenges.

    The latest G2P solutions store and retrieve products or SKUs more efficiently in high-speed picking applications. Buyers can now choose from a range of robotics-based G2P solutions that combine warehouse automation software with a range of autonomous mobile robots (AMRs) from firms such as Geek+, Addverb, Grey Orange, and many other vendors worldwide.

    Functionality of robotic-based G2P systems is rapidly expanding, making warehouse robots a more cost-effective automation investment. As a result, G2P and AMRs are the fastest growing product segment in the material handling automation space, with AMRs for the first time outselling automated guided vehicles (AGVs) in 2021.

    Robotic-based G2P storage and picking systems are now providing compelling ROIs and being widely deployed by small, medium, and large businesses with B2B, e-com, and omnichannel order fulfillment operations.

    Learn more Numina Group’s G2P Solutions

    For example, a company with 3,500 SKUs shipping 3,000 to 4,000 orders daily, implementing a small scale robotic G2P solution will reduce order fulfillment picking and replenishment labor costs while generating a rapid return on investment.

    The Key to Success? Design First, then Compare and Select the Technology

    Successful warehouse automation initiatives should begin with an engineering design study to determine and create a roadmap to implement the right blend of process improvements, automation technologies, and software requirements required to accomplish the project goals.

    During the design study, data analysis will determine which types of warehouse automation such as G2P systems, automated conveyor picking systems, pick-to-light, pick-by-voice, or AMR-based batch cart order picking systems best fit the operations requirements.

    If the design study recommendations indicate a G2P solution will provide a compelling ROI, the next step is to perform unbiased due diligence to compare and contrast the performance of various G2P systems.

    This process should be performed by an independent warehouse automation systems integrator that evaluates technologies and recommends the right blend of technologies that will provide a solution with the most significant efficiency gain.

    An engineering design study will compare and define the proper blend of pick, pack, and ship automation and calculate the ROI of a goods-to-person investment. For example, a warehouse with 300 to 400 high-velocity SKUs may be better served by a system that stores and picks the highest velocity items from carton flow or pallet positions along a conveyor line.

    If there are thousands of additional skus moving at medium and slow velocity blending a high-speed pick line and a G2P system can better optimize performance efficiency of the automated picking and storage system.

    During the design process, another essential factor to consider is the rising cost of warehouse real estate. Factoring in how to best optimize the facility’s building height with technologies that can efficiently store and pick products from the floor to the ceiling will drive a higher return on investment.

    Today’s warehouse storage automation technologies increasingly use denser and higher storage technologies to extend the life of existing facilities and reduce the required building footprint for new distribution centers.

    G2P Picking Performance Rises to 250 to 350+ Picks Per Person-Hour

    Gone are the days when warehouse operations could remain competitive by relying on a manual paper-based order fulfillment operation. Paper-directed pick, pack, and ship processes are very labor intensive and require more supervisor/management positions.

    The picking rate for individual workers in manual paper-based picking operations averages 60 to 90 picks per hour, with low primary picking accuracy rates due to human error, resulting in additional labor hours for QC and secondary checking.  

    The de facto standard rate obtainable from the latest generation robotic G2P picking systems is between 250 to 350 items per person-hour at a pick station, with picking accuracy of 99.9% or better. This speed and accuracy are critical in a same-day order fulfillment operations to keep up with e-commerce and B2B customer expectations.

    AI robotic software advancements are helping to drive significant performance gains. This is accomplished by AI continuously looking at SKU velocity movement to optimize and automate the product storage slotting locations, reduce the robots’ travel, and present an optimized batch of orders to the picking stations to achieve worker pick rates of 250 to 350+ lines per hour.

    The entire warehouse pick, pack, and ship system performs at the highest level when orchestrated by a top-tier Warehouse Execution and Control System, WCS-WES software platform. This software, such as Numina Group’s Real-Time Distribution Software, RDS, manages and optimizes order release for G2P and the other warehouse automation technologies that increase productivity, lower manual labor dependency, and generate a rapid return on investment.

    Ready to learn more? Contact the Numina Group today. 

    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. 

    We’re excited to invite you to join us at Modex 2022 Booth #B1813 to discover how we blend pick, pack, and ship automation that together drives the greatest gains in DC profitability. 

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