NuminaGroup

Author: Jennifer Maloney

  • Select a Picking Technology to Drive Productivity Gains

    Select a Picking Technology to Drive Productivity Gains

    Select a Picking Technology to Drive Productivity Gains

    Jennifer Maloney
    March 20, 2020

    Order processing speed and fulfillment accuracy are vital requirements to building a successful business, allowing distribution companies to remain competitive and meet same-day order delivery demands.

    To achieve a fast, low cost, and accurate business model, distribution centers (DCs) are turning to leaner processes managed more efficiently, using automated order fulfillment technologies proven to reduce costs, improve accuracy, and reduce the reliance on manual labor.

    Designing and selecting the right processes and implementing the right warehouse automation solution is complicated without a knowledgeable partner.

    The Numina Group has been implementing automated pick, pack, and ship distribution operations focused on streamlining costs for over three decades matched to the clients’ requirements. 

    Pick by Voice, Pick to Lights, AMR Robots, and More!

    With 55%¹ of a DC’s operating costs consumed by order picking, Numina Group focuses on processes and technology that provide clients’ the best ROI to enhance their order fulfillment operation. Our solutions consistently exceed performance specifications, delivering higher accuracy and improved operational profitability.

    Voice-Picking Technology

    Voice-directed picking simultaneously improves operator pick rates and accuracy. Voice technology streamlines the entire operation by directing workers in an optimized travel path, eliminating paper and manual data entry and reliance on paper or a mobile terminal, that require the operator to stop to read.

    Voice picking solutions combine fast, lean voice commands and hands-free scan validation to enforce real-time best picking practices. A worker can be productive in 15 minutes with minimal training time.

    Numina Group’s RDS™ Victory ™ Voice Suite can be bolted on to your existing ERP or legacy WMS to add efficient order release logic, pick to cartonization software, and other advanced warehouse practices to empower your team to pick more orders using 30-50% less labor.

    Pick-to-Light Systems

    High density and high-velocity order picking, especially with small size each pick SKU order profiles, can obtain 400-500 lines per hour picking with pick-to-light technology.

    The combination of a wearable Zebra ring scanner, combined with intelligent message displays at each pick location, directs hands free, fast, and accurate picking productivity. 

    Numina Group’s Pick-to-Light system increases speed and accuracy and operates seamlessly with existing ERP and WMS Systems.

    Robots, Co-bots and Autonomous Mobile Robots (AMRs)

    Research suggests 4 million2 robots will be deployed at over 50,000 warehouses by 2025.

    Numina Group is leading the way, installing AMRs to automate the movement of batch pick carts across multiple pick zones and moving pick completed orders to the automated pack and ship area.

    Voice technology directs the picking and operator movement from zone to zone, eliminating wasted walk time and labor spent pushing carts.

    The combination of voice-directed picking integrated with AMR technology for pushing/transporting batch carts accelerates the performance across the entire pick, pack and ship operations.

    Numina Group’s application expertise and family of advanced warehouse automation technologies are incorporated into RDS™, Real-time Distribution System, our highly scalable Warehouse Execution and Control System, (WES-WCS). Our voice-directed automated warehouse systems boost accuracy rates to 99.9% and allow DC’s to process orders more quickly and efficiently with less labor!

    These are just some of the ways new technology is reshaping the future of efficient DC operations. Numina Group will partner with your team to tailor a solution to eliminate bottlenecks and increase the order flow throughout your operation for maximized profitability. 

    Learn more about order picking options for efficient fulfillment.

    Set up a meeting with one of our automation experts to explore the right solutions that will result in a rapid ROI.

    ¹ 50,000 Warehouses to Use Robots by 2025 as Barriers to Entry Fall and AI Innovation Accelerates. AP News. Mar 26, 2019.

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  • Modex 2020 is Here – What to Expect

    Modex 2020 is Here – What to Expect

    Modex 2020 is Here – What to Expect

    Jennifer Maloney
    March 2, 2020

    As a leading material handling and order fulfillment automation integrator, Numina Group has been designing and implementing more efficient distribution centers that provide clients more profitable operations for over 30 years.

    A warehouse automation design with leaner processes enforced with the right blend of automation technologies streamlines the entire order fulfillment operation to lower labor costs, increase accuracy and order throughput, and provide higher customer satisfaction.

    Join The Numina Group at Modex 2020 and learn more about RDS Pick By Voice.

    We’re excited to invite you to join us at Modex 2020 Booth #7006 to discover how we blend pick, pack, and ship automation that together drives the greatest gains in DC profitability, such as:

    RDS™ Pick by Voice

    RDS Voice requires zero voice training for fast, efficient, and simple to use voice commands/responses combined with hands-free Zebra RS5100 camera-based scanners for SKU and Lot capture to optimize order picking. RDS Voice includes several pre-developed picking processes that optimize batch picking to reduce unnecessary touches and travel times.

    Auto Print Fold Insert (PFI)

    Eliminating costly bottlenecks, PFI automatically prints and inserts one to seven 8.5″ x 11″ packing sheets into different types of carton sizes. By reducing repetitive manual tasks, PFI optimizes labor efforts, cutting nearly 30 seconds or more from every shipment process and freeing up operators to focus on other critical tasks.

    One Step Plus™

    Reducing as much as 45 seconds per carton from shipping operations, One Step Plus™ applies an 8.5” x 11” pack sheet under a removable shipping label with speed and ease. The system is best suited for high volume e-commerce and B2B operations that require a full packing sheet on the outside of the carton.

    X-Press PAL™

    This feature auto applies one or more 4” x 6” pack slips under a removable 6” x 8” shipping label. X-Press Pal pack and ship automation includes inline scan, weigh, the dimension with automatic application of packing slips and shipping labels. X-Press Pal provides a flexible, scalable solution to automate packing slips, compliance, carton content, and shipping labels.

    Put-to-Light Order Consolidation

    Boost zone picking order consolidation productivity by 40-50% by using a sort by light put-to-light operation. Put Walls direct packing from picks throughout a multi-zone distribution center. Put-to-Light Order Consolidation is essentially a pack shelf location with an intelligent display to guild the operators to pack orders faster and more accurately.

    Accelerate the performance in your order fulfillment while boosting accuracy and throughput in pick, pack, and ship rates, Numina Group’s Real-Time Distribution System (RDS™) Order Fulfillment Suite powers the entire solution.

    We provide feature-rich, industry-leading Warehouse Execution Control System (WES-WCS) that easily bolts-on more efficient automated practices to an existing ERP/WMS for improved performance to breathe new life into an existing operation.

    Numina Group is ready to show you a range of efficient automation scalable for mid-size to large DC applications. Catch a glimpse of our automation solutions at Modex and contact us for a demonstration. Stop by and discover our full range of services and technologies at the Modex Show Booth #7006.

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  • How to Automate Pack and Ship Labeling Operations

    How to Automate Pack and Ship Labeling Operations

    How to Automate Pack and Ship Labeling Operations

    Jennifer Maloney
    February 20, 2020

    Pack and ship automation is a top consideration when investigating ways to modernize and optimize order flow in a DC. When comparing your options, it is critical to invest in a solution that includes the right mix of automation technologies – including automatic weight and vision audit, carton dimension measurement software, and technology to automatically print and apply packing sheets and shipping labels. 

    As leaders in warehouse automation solutions, Numina Group’s automated warehouse systems focus on process improvements and automation that streamline the entire pick, pack, and ship operation.

    Automated Labeling Systems Increase Efficiency and Profitability

    Manual labeling is expensive, inefficient, and error prone, resulting in:

    • Mislabeled Products – When labels are applied manually, human error becomes a risk, which can result in shipping the wrong product, shipping to the incorrect location, and lost inventory.

    • Delayed Shipments – Manual labeling processes take time, and in the age of same day delivery, time is money. As more customers expect fast delivery, slower processing speeds cause operations to miss carrier cut-off times. This can adversely affect your profit margin with cost overruns and eliminate your competitive edge because customers will opt for your competitors.

    • Employee Turnover – Repetitive, boring work tasks such as placing cartons on a scale, hand scanning, or keying data to print a label and place it on a box is boring. Repetitive tasks contribute to employee mistakes. A single shipment error can cost over $250 or more to correct and can result in a lost customer.

    When you eliminate repetitive tasks and error proof the labeling process, you can redirect your workforce to concentrate on other more important – and rewarding – tasks that keep them engaged and expand their skill sets.

     

    Numina’s family of advanced automatic print-and-apply labeling solutions maximize order throughput to lower labor costs and increase operational efficiency. Our flexible, scalable print and apply labeling solutions are used in both manufacturing and warehousing facilities to automate the application of product identification, retail and e-commerce compliance, carton content, packing slips, and shipping labels.

    Medical product shipments, B2B, and many e-com B2C order fulfillment operation’s parcel shipments require both a packing sheet, shipping label, and customer specific label applied to the outside of full case and re-packed cartons. The labeling and carrier manifesting tasks when performed manually at a manifesting workstation requires the operator to:

    1. Hand scan the order identifier barcode

    2. Weigh, capture and enter the carton dimensions

    3. Print the packing sheet

    4. Fold the packing sheet

    5. Place the document into a plastic pouch

    6. Apply both the pack sheet pouch and the shipping label(s)

    In a manual operation, the best operators can only process 1 to 2 cartons per minute. Replacing the above manual operation with a Numina Group in-motion high speed print and apply labeling conveyor line automates the scan-weigh dimensioning and application of the pack sheet or a removable packing slip and shipping label. 

    In comparison, a print-and-apply labeling system can eliminate the cost of 4 to 5 operators per shift, saving $28,000 to $30,000 a year per employee.

    Get efficient and investigate the advantages of automated print and apply labeling – managed by Numina Group’s RDS™ software platform. Our family of print and apply labeling systems are designed to meet the most demanding applications and are tailored to specific labeling requirements.

    Check out our X-Press PAL™, One-Step™, and One-Step Plus™ labeling solutions that:

    • Eliminate manual labor

    • Increase shipments for higher distribution efficiency

    • Eliminate costly shipping errors

    • Get a rapid ROI

    Numina’s RDS™ WES-WCS Real-time Distribution Software is a modular and scalable Tier 1 Warehouse Execution and Control System that includes a complete family of order fulfillment automation modules to control and manage material handling and warehouse automation technologies that streamline the pick, pack, and ship order fulfillment operation.

    Increase operation accuracy and profitability by investing in an efficient automated labeling solution. Speak with one of our warehouse automation specialists and discover the advantages of pack and ship automation on your business’ bottom line.

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  • How Numina Group’s Automated WES-WCS Empowers Your Operations

    How Numina Group’s Automated WES-WCS Empowers Your Operations

    How Numina Group’s Automated WES-WCS Empowers Your Operations

    Jennifer Maloney
    February 14, 2020

    Order fulfillment labor costs are the largest cost in an e-commerce operation. In order to remain profitable, it is imperative to keep these costs in check.

    We are committed to developing and delivering solutions that lower our clients’ cost per order goals. Numina Group empowers more productive distribution operations with optimized processes and automation technologies enforced and managed by real-time warehouse software that executes more efficient operations.

    Transparency. Accuracy. Efficiency – This is the Advantage of RDS™ WES-WCS

    For over 30 years, the engineers and software team at The Numina Group have gained the expertise to define and apply better distribution practices to increase several key performance indicators across pick, pack, and ship operations. Our expertise enables us to provide solutions tailored to the order fulfillment operation requirements with measurable performance improvements that meet or exceed our customer’s goals. Numina Group’s Real-time Distribution Software (RDS™), the industry’s most complete Tier 1 Warehouse Control and Execution System (WES-WCS), is a key component of the improved performance achieved by our customers.

    RDS™ is a modular, scalable WES-WCS that includes all of the tools needed by your business to integrate pick, pack, and ship automation into more efficient and profitable ecommerce solutions. It integrates with any warehouse management system (WMS) or enterprise resource planning system (ERP), bridging the gap between your order entry, resource planning and order fulfillment technologies. RDS™ operates with real-time (sub-millisecond) multi-function control to execute tasks and business rules with automated material handling equipment. 

    Versatile in nature, RDS™ can enhance multiple DC operations, including:

    • Optimize work paths – Prioritize and release orders efficiently to optimize work travel paths while ensuring orders are complete based on the carrier pick-up time.  One of the most effective ways to lower operational costs is to reduce worker travel time, which accounts for over half your workforce’s day. Integrating voice-picking technology and hands-free data capture, RDS™ can reduce over a third of labor costs by minimizing unnecessary walk time.  
    • Tracking and reporting SKU velocity – Let your WES-WCS indicate when it’s time for re-profiling.  Re-profiling should be done every other month to determine if anything in a B position should be moved to an A location based on seasonality of a given product.
    • Cartonization logic – Save money by minimizing shipping container costs and time spent packing with cartonization logic.  Cartonization logic determines the right box upfront to utilize the most cube space and use less void fill, keeping shipping costs down.  Cartonization logic also directs operators to pick into the shipping carton, which removes the repacking step.
    • Batch cart picking – Take productivity a step further by picking 10 or more orders at the same time directly to the shipping cartons, providing a 40-50% speed gain.

    The above modules are a handful of the RDS™ automation modules available. RDS™ holds the potential to streamline operations, manage picking, packing, material handling, and conveyor systems for consistently higher operational throughput and productivity. The software includes data capture tools to view and report operational labor and order detail. Let Numina Group show you how automating your distribution operations will improve throughput, accuracy, and increase profitability. Contact our warehousing experts today.

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  • The Right Voice Picking Solution Eliminates Shipment Errors in Your DC

    The Right Voice Picking Solution Eliminates Shipment Errors in Your DC

    The Right Voice Picking Solution Eliminates Shipment Errors in Your DC

    Jennifer Maloney
    February 7, 2020

    You see a watch online. You buy it. You select next-day shipping and pay ten dollars extra. Your watch arrives three days later…and it’s the wrong color!  When that scenario happens, it frustrates customers and diminishes repeat purchases. Research estimates that the costs of miss-picks can drain profits of $400,000 per year from an E-com or B2C order fulfillment operation.

    In the age of the Internet World, time and accuracy in order fulfillment operations are critical drivers to same-day delivery deadlines. All DC operations desire speed and zero error picking due to increased cost competition. With a few search commands, customers can shop virtually any product price and delivery, and if your DC wants to compete you must be able to fulfill more orders in less time, at the highest accuracy and lowest cost per order fulfillment method. The days of a DC relying on a paper-based or a mobile barcode terminal and manual data entry process are over. It is not only slow and inefficient, but it is also a source of errors. Statistics show that 1 in every 35 terminal based data entries can result in an error.

    As leaders in warehouse automation, Numina Group’s RDS Voice™ Suite is designed to include several tools that enforce efficient and highly accurate order fulfillment processes. RDS Voice™ can boost accuracy up to 99.9% with increased speeds, without extensive operator training. By enhancing accurate productivity, RDS Voice™ can:

    • Secure a brand’s trustworthy identity
    • Meet same-day delivery expectations
    • Reduce labor costs 
    • Reduce retailer chargebacks
    • Stop errors from leaving the DC

    Why RDS™ Voice? The Answer is Obvious.

    To further illustrate the capabilities of RDS Voice™, Numina Group CEO, Dan Hanrahan, explains the opportunities voice-picking can provide to your operation.

    What makes voice picking indispensable in today’s operations?

    Voice technology combined with hands-free barcode scanning has been shown to yield some of the highest performances and productivity gains in the industry. That’s because it directs your workers in a uniform manner, enforcing lean improved picking practices. Voice plus hands-free barcode data capture drives and measures order processing times. Order processing and labor are measured and reported; resulting in faster and lower error operations.

    What’s are the top obstacles warehouses eliminate with RDS Voice™?

    Inconsistent operator productivity and inability to enforce and measure accuracy and labor. Even the best employees in a DC relying on paper-based order release and an operator picking by paper or paper and a mobile tablet or barcode terminal-based picking system will be limited by having to rely on tribal knowledge, keying in data, and switching to different screens. Those processes will slow down the operator and can produce a 1-2 % error rate! No DC can survive this error rate, so the operation will require almost a 100% secondary quality check of order picking, deploying close to the same amount of labor to QC orders in the packing operation. 

    The RDS Voice™ Suite includes several combined software modules to deliver best in class performance single touch pick and pack, including; order release optimization to direct a batch order picking process in each picking, and cartonization logic to direct pick and pack directly to the shipping carton. Additionally, the software suite prioritizes orders and directs more efficient fork truck, batch order cart and conveyor-based walk/travel paths to eliminate wasted order processing time. Combining several parameters to optimize and manage several parallel order picking strategies can result in up to double the operation’s order picking rates.

    The Zebra RS5100 finger mounted camera-based ring-scanner can rapidly scan items

    RDS Voice is multi-modal – combining voice directions with hands-free barcode scan verification of pick location and product barcode and or voice prompts, directing lot serial data capture and keeping the operators working in a hands-free, eyes focused work environment – free of paper or handheld terminals.  The pickers wear the latest generation Zebra 5100 finger mounted camera-based ring-scanners to rapidly scan items. Voice confirms the required quantity picked. 

    How hard is it for workers to adjust to this new picking system?

    With RDS Voice™ new employees become instantly productive

    RDS Voice™ is simple to use, requiring zero voice training and requiring only a handful of voice commands to master. Minimal training of about 30 minutes means less management time onboarding employees, so a new employee becomes instantly productive. This allows temporary workers during peak periods and seasons to be productive on day one!

    What are some considerations customers should consider before implementing a voice picking solution?

    Before implementing voice, we start with assessing a client’s current operation, to lean-up the processes and uncover and resolve operational bottlenecks and throughput constraints. We use our firm’s three-plus decades of warehouse automation expertise to create and define an efficient pick, pack, and ship operation that minimizes labor usage and eliminates wasted touches across the entire operation.

    How does the Numina Group help clients successfully integrate a voice solution?

    Before launching any automation initiative, we collaborate with the customers to define the project and performance metrics goals. We review and agree upon the processes, pick-rates, and the automation investment objectives. These are written into the description of the operation, including the system acceptance test plan. The solution requires a plan to measure and verify success – results achieved or expectations exceeded.

    To explore the benefits of RDS Voice to drive and enforce improved productivity and accuracy across your entire order fulfillment operation, contact Numina Group today for a free consultation on how our voice suite will increase customer satisfaction, improve profitability by eliminating costly miss-picks and missed shipments once and for all.

    Kickham, Victoria. Picking technologies: When inaccuracy leads to lost costumers. DC Velocity. Apr 26, 2018.

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  • Automation Solutions to Eliminate Warehouse Constraints

    Automation Solutions to Eliminate Warehouse Constraints

    Automation Solutions to Eliminate Warehouse Constraints

    Jennifer Maloney
    January 30, 2020

    Technology is changing distribution operations to meet the demand of customers wanting faster services/shipments. According to research conducted by Invesp Co.,  96% of customers associate fast as same-day delivery, so faster speed in the order fulfillment operations is essential. Moreover, faster operations impact customer loyalty. For example, according to a consumer study conducted by Oracle Retail, 13% of surveyed customers reported avoiding a retailer if their delivery is late. To maximize customer satisfaction within the on-demand economy, Numina Group simplifies workflows, improves processes, and applies the right blend of automation so your operation doesn’t fall victim to warehousing constraints, such as:

    • Poorly slotted inventory storage
    • Missed carrier cut-off shipping costs
    • Wasted labor in costs order processing
    • Inefficient manual labeling and manifesting

    Our warehouse automation systems include enhancements such as automated print and apply labeling systems that eliminate processing bottlenecks in packing and shipping operations. In partnership with your team, Numina Group explores fulfillment optimization practices that combat constraints, reduce costs, and increase operational efficiency across the entire pick, pack, and ship operation.

    Three Ways to Maximize Warehouse Throughput Efficiency

    Maximize Warehouse Efficiency with Automation

    1. Explore the advantages of a top-tier Warehouse Execution and Control System: Numina Group’s RDS, a WES-WCS will accelerate your DC performance. RDS™ optimizes order release to boost picking efficiency and enforce continuous daily productivity gains, even throughout peak season, with expanded order and labor tracking visibility throughout your DC. RDS™ warehouse automation solutions easily integrate with your WMS and ERP systems.
    2. Enhance worker performance with Voice Directed Picking or Pick by Voice: Raise your picking accuracy to 99.9%. RDS™ Voice directs your workforce and keeps them moving with less wasted labor, including optimized walk paths, fork truck routes and less time spent viewing and keying in data.
    3. Eliminate manual packing and manifesting labor with in-line scan-weigh-dimensioning and Print and Apply Labeling Solutions: Process thousands of cartons per hour fast and accurately, so you meet same day shipping demands. Print and Apply will increase order throughput and can scale from mid-size to the highest volume DC operations.

    Numina Group has been focused for over 30 years on warehouse design improvements and automation systems. We will help you identify warehousing order fulfillment constraints and provide the right solution to optimize your operation. Contact our warehousing experts for a comprehensive assessment of your current DC operations, and stay ahead of the on-demand economy.

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  • Benefit from the GO Zebra Trade-In Program with Numina Group

    Benefit from the GO Zebra Trade-In Program with Numina Group

    Benefit from the GO Zebra Trade-In Program with Numina Group

    Jennifer Maloney
    January 23, 2020

    We’re excited to announce our recent partnership with Zebra Technologies, the industry’s leading mobile device automation manufacturer. Together our warehousing automation teams are implementing the latest technologies to manage better processes, boost operational efficiency to reduce labor costs, and increase order completion times and accuracy.

    One example of this is Numina Group’s real-time voice picking application executed on Zebra’s latest generation Android-powered wearable computers. These latest wearable computers seamlessly connect to Zebra’s wireless headsets and the just-released Model RS5100 wireless camera ring scanner. RDS™ Voice combines hands-free 2-D barcode scanning with voice commands to convert pick and pack validation into a single touch operation.

    The advancements in Zebra’s wearable computers increases ergonomics and speed in the voice picking application by 5%-10%, further optimizing voice picking’s performance advantages and improving accuracy in piece picking, full case picking and kitting, with lot and serial capture in medical, food cold storage, and other applications. 

    Advantages of True Full Mobility

    Go Zebra Warehouse Full Mobility

    Faster performance in the Distribution Center provides higher quality customer service and reduced-order pick and pack completion times, ultimately improving delivery times, which is a crucial necessity in every DC regardless of the size or business. Studies suggest at least 65% of retailers today offer same-day delivery; therefore, it’s time to implement technology to increase the speed and accuracy in your fulfillment operations in order to compete. By integrating a voice-directed mobile workforce in your DC you’ll benefit through:

    • Faster onboarding – Because warehousing is one of the top industries facing high and expensive workforce turnover rates, simplified employee onboarding is vital to driving down costs. Devices such as Zebra’s TC52 handheld computers have familiar Android touch-screen interfaces, so new employees do not have much of a learning curve. Furthermore, the compact touch-screen computer streamlines workflows by combining long-range connectivity networks with omnidirectional data capture, so employees only need to be trained on one device instead of several.
    • Voice-enabled productivity – Speaker independent voice-picking requires zero operator voice training. Operators, especially new employees, can be productive the first hour on the job.  When deployed on rugged, wearable hardware, such as the WT6000, multi-modal speech-directed picking, combined with a hands-free, eyes focused picking process boosts productivity by 20% to 40% with accuracy of 99.99%, reducing errors.
    • Unmatched ergonomics – Productivity and ergonomics go hand in hand, which is why Zebra’s RS5100 latest 2-D Omni-directional barcode scanner is light and designed to fit on your index finger. This small, fast scanner captures item and serial number barcode data in milli-seconds and minimizes worker verification tasks. With a 12-hour battery life, the RS5100 can perform 14,400 scans in a single charge. Furthermore, thanks to its rugged design, the scanner reduces repair visits, securing maximum uptime and lowering total cost of ownership.

    Zebra RS5100 and WT6000 Used in Warehouse Scanning

    Numina Group can help you modernize your order fulfillment operation and eliminate the reliance on people, paper, and obsolete Windows-based terminals by taking advantage of the GO Zebra Trade-In Program. The program provides cost-savings, with a trade-in program for your warehouse productivity upgrade. We’ll assist you in purchasing qualifying devices and submitting the claim form. When you trade-in legacy RF terminals, you’ll get cash rebates up to $200 per device or a cost concession.

    The immediacy of the Internet World demands higher warehouse productivity. As leaders in designing efficient automation solutions, Numina Group will partner with you to help define and implement a DC optimization strategy tailored to your needs. Contact our warehousing specialists today to see how better processes managed with the right automation technologies will optimize your order fulfillment operation.

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  • Peak Season is Done, but Your Warehousing Constraints Persist

    Peak Season is Done, but Your Warehousing Constraints Persist

    Peak Season is Done, but Your Warehousing Constraints Persist

    Jennifer Maloney
    January 16, 2020

    As expected, the 2019 holiday season shattered previous sales marks, ushering in nearly $720.3 billion, of which $9.4 billion came solely from Cyber Monday shopping through distribution giants such as Amazon and Walmart. While it will still take time to calculate the precise number of holiday profits, businesses nationwide must also be aware of the potential loss. Although peak season brings in a welcome surplus in profits, it also highlights previously overlooked inefficiencies in the warehouse. 

    Although there are still 322 days till the next holiday season, automation experts at the Numina Group are already at work to resolve common warehousing issues that could drain your peak season profitability. By deploying leaner processes managed our industry-leading real-time distribution software and warehouse control systems we equip warehouses and distribution centers (DC’s) nationwide with better operational efficiency that streamlines order volume, empowering you to confidently handle volume growth in and out of peak season.

    Seven Deadly Warehousing Pitfalls

    Warehousing Optimization in the Peak Season

    Whether it be inaccurate order fulfillment or wasted labor efforts, inefficient warehousing can cost as much as $100,000 per hour in downtime, $20 per mis-shipped package, and a lost client loyalty. While every warehouse faces unique challenges, there are a few warehousing issues that seem to resonate with multiple facilities year after year, such as:

    • Too much inventory — To avoid costly out-of-stocks during the busiest day of the year, many companies choose to overstock to keep up with surprise demands. However, a lack of an organized inventory management system can lead to overcrowding, creating confusing pick paths, wasted space, lost products, and small packing spaces. These ultimately contribute to elevated worker stress and missed/inaccurate orders.
    • Unforgiving drop shipping — When shipping on behalf of other businesses such as Amazon or Walmart, shipping rules must be closely followed lest they turn your business away. Errors such as missed delivery dates or wrong shipping labels can lead to millions of lost revenue as companies may reject you and favor your competitors. 
    • High seasonal labor costs — Seasonal warehouse salaries average near $11 per hour, yet this does not account for training times, which may take longer than expected if other inefficiencies are present. Furthermore, as expected with the holidays, seasonal labor costs also include overtime, weekend pay, and holiday pay.
    • Missed delivery dates — Labor shortage and lack of inventory transparency result in missed delivery dates as your workforce encounters more obstacles to pick, pack, and ship orders. Simply put, a smaller inexperienced workforce cannot handle high order volumes normally attributed with peak season.
    • Inadequate picking routes — Longer traveling routes and manual data entry both lead to more inaccurate orders, which drive up costs with return fees.
    • Missing paperwork — Every part of your warehouse operation is important, down to the smallest labels. Wrongly printed or illegible labels can greatly impact your workflow since crucial product information -like shipping address or storage instructions- are no longer available. Wrongly printed labels can lead the right package into the wrong hands, creating a nightmare scenario for your customer service team.
    • Overwhelmed delivery services — In 2018, the United States Postal Service delivered nearly 900 million packages during the holiday season alone. Because every year brings an overwhelming increase in shipped order, it is important to stay ahead of mailing dates stipulated by your courier service and avoid last-minute shipping at all costs. 

    If any of these problems sound painfully familiar, do not hesitate to contact our warehousing specialists for an in-depth optimization plan for your current warehouse operations. Be sure to join us here again next week as we uncover how the Numina Group implements specific solutions to address the problems discussed today and how superior processes enforced with the right software and latest technologies drive higher business efficiency and profitability.

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  • How to Achieve the Highest ROI in a Warehouse Automation Investment

    How to Achieve the Highest ROI in a Warehouse Automation Investment

    How to Achieve the Highest ROI in a Warehouse Automation Investment

    Jennifer Maloney
    November 22, 2019

    Before embarking on a large-scale warehouse automation initiative, it’s important to first determine the ROI that can be expected.

    What does it take to calculate a realistic and obtainable ROI?

    The answers can be obtained by conducting a detailed analysis – pre-project – to understand the financial savings and operational improvements to be gained by automating order fulfillment.  

    Warehouse automation technology, managed with the right software, offers the greatest potential to vastly improve distribution center (DC) performance and profitability. 

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

    However, before selecting automation technologies, customers need to know:

    • What are the business objectives?
    • What are the upfront and operating costs?
    • What are the yearly savings based on current and future order volume growth?

    The way to gather objective answers to these questions is to partner with an independent warehouse systems integrator like the Numina Group to help you determine optimal warehouse automation solution for your specific operations.

    The Warehouse Automation Landscape

    Hundreds of warehouse technologies are available today that can deliver attractive productivity gains in order fulfillment operations. But it is impossible to determine an accurate ROI without first evaluating the gains that can be achieved through process improvements, followed by an objective review of all possible technology solutions. 

    For example, especially for a mid-sized DC, investing in the latest generation shuttle systems and other advanced automated pick, pack, and ship technologies may have a minimal impact on ROI.

    Automating an order fulfillment operation for optimal efficiency requires more planning and analysis than the step of selecting equipment. It also requires conducting detailed research to determine which technology option will the greatest impact, and which systems integrator offers the right application knowledge and software expertise to integrate the solution with your existing ERP and WMS systems.

    Learn More About Numina’s Warehouse Automation Design Services

    The Role of Warehouse Execution Software (WES)  

    Today, an end-to-end warehouse automation system is comprised of numerous software and material handling technologies such as such as voice technology, wearable computers, pick-to-light systems, autonomous mobile robots (AMRs), goods-to-person systems, and automatic conveyors.

    The best way to ensure that your automation project will be a success is to implement a warehouse execution platform such as Numina’s RDS™ WES-WCS solution to integrate and orchestrate all of these technologies for maximum efficiency and performance.

    RDS is the industry’s most complete modular and scalable Tier 1 Warehouse Execution and Control System (WES-WCS). RDS integrates with any ERP/WMS System.

    The Crucial Role of a Warehouse Systems Integrator

    Investing in warehouse automation leads to improved accuracy, lower labor costs, and streamlines distribution center (DC) operations. The warehouse system integrator’s role is to ensure that all three of these project goals are achieved at the highest levels.

    The integrator’s work begins in the project’s initial conception stages, well before the system purchase or go-live date. A knowledgable integrator is integral in helping the customer develop lean design plan with improved processes managed by the right blend of technologies to achieve the desired ROI. 

    Blog: The Crucial Role of Systems Integrators in Warehouse Automation

    As an independent systems integrator, Numina Group offers the breadth of industry and technology experience to help businesses realize what is achievable within a defined budget.

    We achieve this by conducting an in-depth process that includes designing and brainstorming sessions with the client to determine which technologies will drive the highest ROI within a current or new operation and how the automation will work seamlessly with the business system.

    Business Factors to Consider Before Automating

    When it comes to automating a DC, the first step is to understand the current operation and processes, then evaluate the benefits obtained with incremental best practices improvements, such as, slotting, ergonomics.

    Also, if changes are made, they need to be evaluated to determine the impact they will have on reducing non-valued touches throughout the pick, pack, and ship operations. The improved design can then be compared to current operational performance and labor requirements to estimate the efficiencies derived from leaner operational processes.

    This step, once completed, supports a solid technology review to determine the right blend of automation technologies suited for the warehouse operations. It is the combination of lean processes and enhanced automation that yields far higher productivity gains, especially if the solution is comprehensive, holistic, and implemented across the entire order fulfillment operation.

    Process and Technology Solutions that Yield 99.9% Picking Accuracy while Reducing Labor Costs

    Before investing in automation, we consider the positive gains obtained by process improvements such as re-profiling SKU storage based on velocity and travel paths.

    These adjustments in the warehouse typically increase productivity by 10%.  

    The next logical step is to evaluate picking operations. With a more efficient storage and pick path in place, what operation is not eager to achieve 100% accuracy in their picking process along with a 30% reduction in labor costs?

    Improvements in picking are a great investment opportunity, especially since industry averages show that up to 50% of distribution labor is spent in order picking and quality and order checking activities.

    During the design study, the current picking process is compared to and contrasted with the improved processes to answer the following questions:

    1. Is order picking a discrete or optimized batch order process?
    2. Does the operation lack optimized order release software?
    3. Is there cartonization software to support the ability to pick and pack directly to the shipping carton?
    4. Where are the bottlenecks during the peak order processing window?
    5. How much is the labor spend in secondary QC labor and packing operations?

    The goal is to use this data to understand the opportunities to drive productivity and reduce costs across your operation. Once a facility’s processes and performance data have been evaluated for potential rewards, Numina’s design engineering team will evaluate the available picking technologies to determine best the investment choices.

    Warehouse Automation Matched to the DC’s Needs

    Investing in warehouse technologies is a multi-factor decision process. The Numina Group’s team of experts are well suited to assist companies in justifying advanced technologies, such as autonomous mobile robots (AMRs), automated guided vehicles (AGVs), and goods-to-person solutions.

    The latest generation of AMR’s are safe, efficient, and can increase zone picking throughput by automating the movement of pick carts with 15 or more orders at loads of up to 600lbs.

    Blog: Factors to Consider in Selecting AMRs and Goods-to-Person Technology

    Again, multiple factors will be taken into consideration to determine if AMRs or AGRs have a role within the order fulfillment operation. These factors include SKU slotting, velocity movement, pick zone travel distances, travel paths, the AMR’s weight capacity, discrete or batch picking of orders, and operator fatigue or injury from lifting and pushing loads that can approach 500 lbs. or more.

    If AMRs or AGVs are indeed the right technology and will generate a savings in labor of 20% or more, for example, a mid-sized DC with 20 employees per shift, could still be a 3+-year ROI.

    However, if the company is growing at a 10-15% rate, and finding difficulty recruiting and retaining good workers due to fatigue and ergonomics issues that can be eliminated with the use of AMRs, then the investment could indeed be the best choice for the 5-year growth objectives.

    Factors Driving the Total ROI

    Companies of all sizes have access to game-changing technologies, so finding the answers to your businesses needs takes ingenuity, creativity and experience.

    Consider all the above factors when embarking on the define and design process. Partnering with a warehouse design and automation specialist like The Numina Group prior to the investment selection will ensure you obtain the best return on investment, ROI.  

    Contact us today for a complimentary consultation to assess your warehouse automation options.

    Learn More About Numina’s Warehouse Automation Consulting Services

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  • Seven Steps to Prepare for Peak Season

    Seven Steps to Prepare for Peak Season

    Seven Steps to Prepare for Peak Season

    Jennifer Maloney
    September 10, 2019

    Have you walked into a retail store recently and noticed that the Halloween decorations are already in full swing?

    retailers are beginning to display Thanksgiving décor, so Christmas decorations are right around the corner!  If you’re thinking hey, it’s only September, you are already behind the curve in preparing for peak shipping season.  We see it every year, it’s called Christmas Creep, and it’s making its way into online experiences as well.

    Distribution centers need to start ramping up for the cyber holiday shopping season earlier and earlier.  If your DC is continually seeing a large percentage of orders moving to e-com shipments and you have not prepared for the increase in this year’s cyber season, you could disappoint customers with delayed shipments.

    The cost of a late delivery can result in losing a customer forever. One of the most challenging elements for an Omni channel distribution operation with a growing blend of e-com fulfillment is having an efficient process to manage the ability to ship e-com orders. While it is too late to invest in a blend of automation to streamline e-com pick, pack, and ship for the 2019 Holiday Season, it is the perfect time to schedule a consultation with a knowledgeable expert about warehouse automation process improvement design solutions.

    Here are seven steps to take to prepare for peak season.

    Think about Slotting Practices

    It is not feasible to redesign the layout of the entire DC before the holiday ecommerce season is in full swing, but there are steps to take to make certain that products travel through the warehouse in the most efficient manner possible. An effective slotting process will result in your highest movers being stored in the most optimal locations in your facility – with easy accessibility, at both the storage location in the DC and placement on a shelf or rack.

    Consider how you are adjusting for peak season inventory in your warehouse.  Will the item be picked individually or as a full pallet? You want to slot to keep travel time down and the number of touches an item receives as low as possible.  Your slotting strategy should make your picking processes more efficient and accurate.

    Consider implementing a batch picking strategy. Instead of filling one order at a time, a picker will pick multiple orders (batches) at the same time.  This makes sense if there are a few very popular SKU’s that comprise a large percentage of orders.  Keep in mind that any changes made to improve throughput must also ensure accuracy. Software that manages orders, inventory, and pickers must be able to handle the new process.   Shipping the wrong item, especially at Christmas, is a sure way to lose a repeat customer.

    Lean-up the Packing Operation

    Have the most popular shipping carton sizes pre-made and staged at the packing stations or pack lines. If you can eliminate the pack operator’s task of manually building cartons, you’re eliminating 20 to 30 seconds from every carton shipment.

    Limit Congestion

    Because the volume of product being shipped will increase, there will be more products on the floor. It is important to limit congestion, which may impede workflow. More frequent replenishment often helps to keep the aisles unobstructed. Also, clear signage directing pickers to different areas is very important, especially if you plan to hire temporary workers who may not be as familiar with your DC as full time staff.

    Calculate Your Staffing Needs

    If you are going to rely on temporary or seasonal work to cover increased demand over the holidays, start hiring a few weeks earlier and train them before the season starts.  Think about how much time is wasted by having your best workers training or directing temporary workers during peak periods.

    Update Your Maintenance

    Make sure you have spare parts on hand. While unexpected downtime on an essential piece of equipment is never a good thing, it can be much more of a headache during peak season.  Now is the time to plan for the unexpected. Stock up on spare parts that have the greatest potential to break.  Practice preventative maintenance tactics for all systems.  Make sure your support agreement is active and up to date. Your people and technologies must be able to continue to perform with higher throughputs and demand.  That’s why it’s critical that you take the time now to ensure that your equipment will be able to perform under increased stress from the holidays.

    Update your Training Processes and Procedures

    It is important to have best practice processes in place.  Finalize and test new training initiatives before the stress and confusion of peak season hits.  Hint for the future – Voice Picking using a speaker independent voice engine requires no voice training, so even temporary labor and seasonal employees can be productive in minutes.

    Plan for the Future

    Here are some key data 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 were the highest number of customer complaints? Accuracy, missed delivery dates etc.?

    Once the season is over, start planning for next year.  Consider the major challenges that you faced during the peak season that you need to prevent going forward.  Make a plan to improve missteps. Identify the bottlenecks within your facility, and create a budget for larger initiates. Investing in automation that streamlines e-commerce will pay dividends throughout the year by creating a more efficient distribution process.

    Numina Group can help you choose the right blend of automation that will scale with your business, such as voice picking, scan-weigh-dim, and print and apply labeling. Integrating automation and process improvements is the best way to iron out inaccuracies, cut labor costs, and remove dependence on temporary workers.

    The right Voice Picking technology makes training time practically nonexistent.  Voice, especially speaker independent voice technology can make your best workers 25-30% more productive.  Voice can also make temporary workers productive in minutes. Investing in Voice Picking is the best way to improve accuracy and reduce your reliance on temporary workers.

    Numina Group’s order fulfillment automation solutions are modular, allowing you to focus on the right blend of automation technology to realize benefits that drive a rapid ROI.   We have over thirty years 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.

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