What’s driving AMR adoption in the warehouse, and should you join the ride?

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Warehouse robotics has long been pinpointed as a disruptive force to reshape the face of modernized warehousing. Now seen as an indispensable support for the changing workforce, robotics investments have surpassed $22 million worldwide, illustrating the digital transformation in today’s supply chains. While e-commerce and shortages have been responsible for most supply chain shifts, AMR adoption can be traced back to a few common factors such as:

  1. Rise in SKU numbers – As more e-commerce stores open, more products flood supply chains, increasing order throughput rates within smaller workforce pools.
  2. Steady increase in labor expenses – Studies show that labor expenses account for over 60% of total operating costs, surpassing rent, utility, and technology expenses. As labor shortages continue to affect industries, these expenses are only set to continue.
  3. Higher likelihood of worker injuries – Around five in a hundred workers are expected to get injured while on the job per year per warehouse. While that may seem like a small probability, one injury can cost companies up to $38,000 in direct costs alone.
  4. Higher likelihood of mixed pallets – With warehouse spaces also increasing in rental price, facilities are more likely to store mixed pallets and split cases to ensure greater product variety. This may create future complications as workers must travel farther throughout the facility to assemble orders.
How do AMRs fit into new warehouse challenges

As customer expectations continue to shift over time, new challenges are only expected to rise. Consequently, intelligent AMR fleets such as the ones built by Zebra’s Fetch Robotics improve modernization strategies by working alongside other future-forward technologies to…

  • Automatically differentiate similar products with RFID scanning during the pick process. Because tags store multiple codes at once, RFID data capture empowers teams by directing AMRs fleets to the correct location based on captured and shared data via the WMS.
  • Reduce employee travel time around the warehouse with roller-top AMRs that meet picking teams in designated locations. In doing so, teams no longer need to move between aisles since AMRs can just bring the order to them for picking and then move the pallet to the next step of the order fulfillment process.
  • Prevent worker injuries that stem from carrying heavy loads or traveling down the same routes as forklifts and other heavy machinery. Next-generation AMRs are equipped with sensitive motion sensors to spot workers and avoid collisions.
  • Track split cases for streamlined picking via your preferred handheld device. Since AMRs can carry up to 600 pounds per device, multiple orders can be transported at once, increasing order throughput while navigating through different pallets with less errors.

An efficient robotics solution is often accompanied by several supporting technologies to simplify deployment and streamline workflows for less bottlenecks. The first step to modernization is a careful in-depth workflow assessment to outline needed technologies and goals within your solution. To learn more about how to get started, contact Avalon’s modernization experts.

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4 New Technologies You Should Keep an Eye for in Your Warehouse

E-commerce alone has been responsible for over 4 trillion in revenue within the past years, accounting for a much larger significant part of global retail sales compared to five years ago. Combined with current labor shortages and breakdowns in international logistics systems, warehouses must navigate through a series of challenges to keep up with demands and growth. Studies conducted by leading automation experts have highlighted the following challenges affecting today’s warehouses and distribution centers:

  • Labor shortages and low retention rates
  • Low warehouse capacity compared to higher product demand
  • Rising number of dynamic e-commerce transactions (BOPIS, rentals, direct-to-customer, etc.)
  • Employee safety, particularly at the loading dock, where 25% of worker accidents happen
  • Adaptable cyberthreats targeting digital devices, including peripheral hardware like printers

It’s important to remember that these issues come alongside challenges unique to individual warehouses such as location, cold storage management, peak seasons, and other possible impacts. To minimize downtime and complications, Avalon partners with Zebra Technologies to highlight four solutions developed to secure productive uptime amidst today’s challenges. 

  1. Consolidated data capture and processing – Manual data entry is both time-consuming and complex, making it difficult for new hires to adopt. Moreover, inefficient reporting can create problems later down the road if data isn’t readily available for audits and compliance verification. As warehouse management systems are selected, supporting devices should streamline automated data capture and computing for real-time inventory and workflow visibility. Zebra’s newest WS50 wearable computer exemplifies this by integrating an intelligent scanner within a lightweight touchscreen device that mounts to the worker’s wrist and connects with the WMS. 
  2. Automatic Mobile Robots (AMRs) – To address both labor shortages and employee safety concerns, AMRs come alongside the human workforce to empower faster picking with less travel time since they can move pallets and orders between loading docks. Although many warehouse workers may fear robots will displace their jobs, studies show that at least 73% of decision makers are actually looking to support human labor with robotics in partial automation plans. This means employees would be empowered to work smarter with less physical strain while robotics do the literal heavy lifting. 
  3. Touch-free validation scanning – One in five online shoppers will return an order because the wrong item was shipped. As a result, order validation has become crucial to securing long-lasting customer loyalty. Because workers face shorter delivery timeframes and increased thoughts, touchless order validation through systems like Zebra’s SLS portals have proven beneficial to check order accuracy without pausing productivity. As orders are validated at the loading dock, warehouses can notify customers of accurate orders, thus also satisfying demands for real-time tracking. 
  4. Adaptable RFID data capture – Because of its 99.9% accuracy rate, it’s no surprise that at least 35% of warehouses are choosing to deploy RFID. However, not every RFID system accommodates varying device types. Adaptable devices like the RFD90 can adjust to iOS, Windows, and Android devices to enable RFID scanning with your preferred device, consequently lowering training times since workers don’t need to upgrade entire handheld systems.  

Small steps can take you far.

While these new technologies represent the latest edge in modernized warehousing, effective adaptability can start with smaller implementations such as automating data capture and reporting or migrating to Android. Programs such as the GO Zebra Trade-In provide a cost-effective start to upgraded modernization. By swapping out legacy devices to newer Zebra hardware, operations can integrate:

  • Automated data capture 
  • Secured data protection
  • Greater device durability
  • Faster printing speeds 
  • Mobile printing 
  • Push-to-talk connectivity
  • Adaptable WiFi support 
  • High-volume printing 

Because every business is inherently unique, Avalon recommends starting an operational assessment before selecting possible modernization strategies. By meeting with a technology expert, businesses can prioritize optimization areas to decide between large-scale implementations or smaller changes. By ensuring scalability, warehouses can best prepare to address new future obstacles that are sure to come.

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At least 41% of decision makers are turning to RFID tracking. The reason goes beyond traceability.

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Past studies have showcased the concerning lack of trust consumers have in food & beverage companies regarding product safety. A mere 22% of shoppers have stated that they fully trust companies to accurately verify product integrity. However, as consumer expectations shift throughout time, effective traceability is no longer the only driving force behind RFID adoption.

Dynamic supply chains involving a variety of similar SKU units in a wide geographical range must not only verify product quality, but also ensure ETAs are met, order accuracy, and seamless data transmission, all with a smaller carbon footprint. For example, current research shows that 77% of shoppers now use a mobile device to initiate a purchase. This means distribution centers must be able to aggregate data coming in from multiple terminals and distribute tasks proactively across the workforce. In other words, real-time RFID visibility could assist with:

  • Reducing inaccurate handling and storage risks
  • Verifying in-stock materials as orders come in
  • Tracing manufacturing workflows to prevent recalls
  • Simplifying real-time order tracking for customers
  • Connecting order picking teams with real-time demands
  • Consolidating several data points onto a digitized form for easier auditing

When “high-speed” meets “high-volume”, only the toughest solutions will do.

Distribution centers now require flexible and durable technologies to satisfy multiple demands at once. That’s where next-generation devices like Zebra’s new RFD90 Ultra-Rugged RFID Sled come in handy. Tailored to adapt to leading operating systems and mobile devices, the sled exemplifies RFID’s strides when it comes to evolving inventory management through:

  • Ergonomic design that favors worker comfort and durability
  • Enhancing scanning performance for large workspaces
  • Flexible connectivity options to pair with Android, Windows, and iOS devices
  • Tap-to-pair setup for faster solution deployment
  • Remote device management via pre-installed WiFi 6
  • A variety of charging options to ensure around-the-clock device performance

Learn more about Zebra’s new RFD90 Sled in our fact sheet.

As consumer demands continue to grow, technology can expect to mature alongside them. Reach out to an Avalon expert to learn how you can keep optimizing your warehouse with locationing and visibility technologies designed to thrive in today’s order fulfillment challenges.

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3 Sustainable Tools Breaking Down Communication Barriers in the Modern Supply Chain

Studies show that today’s consumers are far more conscious of a brand’s environmental impact, placing a demand for complete traceability, especially in the food and beverage industry. A mere 20% of consumers truly trust brands to ensure food safety, fueling further skepticism regarding sustainable practices in food distribution. With Earth Day (April 22, 2022), being a few weeks away, companies are encouraged to revisit sustainability plans and ensure proper tracking visibility. As a matter of fact, around 96% of supply chain decision-makers agree that operational visibility provides a clear advantage. Therefore, optimizing sustainable tracking proves to be both beneficial to your brand and your customers. 

How to get started:

While there are several tools available today for sustainable distribution, very few systems prioritize ease-of-use in and out of the four walls. Though indispensable in any automation solution, hardware alone cannot carry to sole weight in securing sustainable traceability. When adding an eco-friendly layer to your visibility solution, consider the following…

1. How are GS1 standards being tracked?

Developed with the sole purpose of facilitating system communication and visibility, GSI standards help ensure products are ready for purchase by aggregating identifiers in a common language. From organic meat to processed candy, products are expected to be identified by markers readable through any system. GS1’s simplicity and compatibility have led nearly 90% of small and growing businesses to adopt its system, also confirming its cost-effectiveness. 

To best leverage GS1 standards, companies are encouraged to verify raw materials, completed products, and shipments display unique GS1 identifiers and any other necessary variable information. Production status should also be easily identifiable, so field teams and retailers know when to expect shipments. These identifiers can be recorded digitally with the help of barcoding or RFID technologies for reduced manual errors. 

2. Can the number of deployed devices be minimized?

More deployed devices per worker maximizes the risks of increased electronic waste. Although several next-generation devices have been optimized to consolidate workflows, food distribution provides additional challenges as devices must be rugged enough to survive drastic temperature changes within one facility. When it comes to field delivery teams, solutions must factor in long distances to verify connectivity is maintained. 

In addition to consolidating workflows through one rugged device, a push-to-talk communication solution may also be beneficial to eliminate two-way radios while connecting field teams and distribution centers without more devices. For example, Zebra’s Workforce Connect app provides instant communication and secured text messaging independent of cellular connectivity, so transportation teams can update ETAs and optimize routes for less wasted fuel.  

3. Are legacy/outdated devices being properly recycled?

Although e-waste composes only 2% of American landfills, it’s responsible for 70% of overall toxic waste. Every effort to minimize toxic waste empowers future generations to live on a cleaner planet. That’s why companies are encouraged to verify decommissioned devices are properly recycled according to local and federal compliance standards. Currently, 25 states are actively targeting electronic waste through mandated recycling initiatives.

As a Zebra Premier Solution’s Partner, Avalon strives to pair proper recycling with enterprise-ready upgrades through the GO-Zebra Trade-In Program. Outdated devices from any manufacturer may be traded in for cash rebates to be used on newer Zebra upgrades. Outdated devices are properly disposed of without compromising the environment or data security through our trusted recyclers. 

If you are unsure on how to answer any of the questions above, it may be time to rethink your tracking system to ensure it meets compliance standards and consumer expectations. Reach out to Avalon’s optimization experts to get step-by-step assistance in assessing your tracking system to best target optimization opportunities. 

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