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What does Automation on the Production Floor Look Like?

Production floors in manufacturing plants need fast and accurate workflows that efficiently manage assets and deliver products. Automation is beneficial in boosting efficiency with control over work-in-process, traceability for recalls, and quality checks before products leave the production floor. Despite labor shortages, studies show that manufacturers still produce 44% more goods than 30 years ago due to factory automation solutions including automated data capture and digitized reporting. Therefore, it is no surprise that an estimated 42% of the time spent on manufacturing tasks will be automated by the end of the year. To remain competitive in the Digital Age, manufacturing facilities must consider the benefits of automating workflows as well as the consequences of delaying modernization.

 

Lack of automation within the production operation pressures your workforce to keep up with high demand influxes without agile tools. Enhanced systems such as automated data capture and sharing can manage operations, track stock levels, and monitor asset performance all in real-time for unbroken productivity. Although automation may take different forms in different industries, businesses can expect the following benefits from intelligent modernization:

 

  1. Increased product accuracy and quality control – Data automation tools like mobile computers can deliver consistent accuracy and speed with minimal variation, improving production rates and product accuracy. You can avoid higher costs from inaccurate production with mobile computers that provide faster-than-ever barcode capture and multi-distance scan engines that improve track and trace on the floor.
  2. Boosted versatility – Mobile technology like computers and tablets can come equipped with powerful extensions that allow businesses to increase security, improve device manageability and more. Expanded features enable manufacturers to capture up to 100 barcodes with a single scan to improve worker efficiency, while data automation delivers predictive analytics and rich data capture so your floor can stay flexible and adapt to rising demands.
  3. Faster return on investment – Dependable automation solutions reduce lead times, lower operating costs and improve output. Rugged mobile computers and tablets out-perform consumer devices and deliver dependable performance to improve the device lifecycles and deliver a higher ROI. Devices like this also help remove the errors of manual operations to deliver controlled and accurate workflows.

 

Speed and accuracy are the top priorities for the production floor. Mobile computers and tablets can help deliver real-time performance to manage operations and improve productivity. Automated mobile computing and scanning solutions deliver:

  • Faster and more efficient workflows
  • Quality checks and control
  • Enhanced visibility and flexibility for recalls
  • Faster cycle times

Automation is quickly taking over manufacturing plants to streamline productivity on the production floor. Learn more about how you can leverage track and trace solutions and rich data capture in your facility.

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4 Ways to Achieve Faster Warehouse Processing

Today’s consumer demands require faster, more accurate, 24/7 fulfillment in warehouses and distribution centers. Businesses need trusted performance to identify, measure, track, and inspect items from production through distribution to deliver goods faster. Increasing numbers of businesses agree that implementing automation is the easiest and most efficient way to achieve fast fulfillment. Studies show that 80% of organizations plan to invest in new technologies to be competitive, while 70% of warehouse decision-makers need to modernize their warehouse operations–but admit they are slow to implement new devices and technology.

 

Warehouses with slower operations run the risk of losing customers, frustrating workers and enabling errors. To prevent these issues, automation experts suggest deploying strategies such as:

 

  1. Streamlining data collection – When workers pause to collect data, they create a significant time drag and diminish efficiency. While this can happen potentially thousands of times a day, an autonomous automated solution can eliminate downtime and free up workers to focus on more skilled, non-repetitive tasks.
  2. Choosing smarter scanning capabilities – Innovative and automated scanning technologies can be affordable, flexible and easy to deploy. Flexibility and easy integration offer simple management to make warehouse operations more efficient and workers’ days easier. Simplified integration also can help reduce training times so warehouses are more prepared for consumer demands.
  3. Implementing flexible barcode readers – Industrial scanners can boost scanning capabilities by gathering data from numerous items at once. Handheld scanners with expanded read ranges and variable-distance barcode reading ensures your workers get the data they need quickly and with fewer steps.
  4. Reducing downtime with automated scanning – Industrial scanning solutions grow with your business and adapt to changing operational demands with flexible and durable designs. Smart automation withstands challenging conditions like warehouse environments to reduce time spent on repairs and maximize mobility.

 

Speed is the top priority when it comes to fulfillment and consumer expectations. Innovative solutions like industrial scanners can improve order picking and packing speeds without compromising accuracy or workflow management. Automated scanning technology provides trusted performance for the distribution process with:

  • Accelerated shipment handling
  • Increased efficiency
  • Decreased downtime
  • Streamlined workflows
  • Improved accuracy
  • Reduced risk

 

Improved warehouse operations and order fulfillment are achievable with innovative automated scanning technology. Learn more about how your business can improve accuracy and decrease downtime to surpass consumer expectations.

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Which Scanning Solution Best Fits Your Operations?

The right barcode scanning solution enhances order fulfillment and asset visibility. For almost 50 years, supply chains have been leveraging barcoding solutions because they can help meet emerging consumer demands, such as fast shipping and 100% order accuracy. Studies indicate that 65% of consumers are willing to pay more for faster shipping and 73% claim they would order more frequently from a vendor following an early or timely delivery. On the other hand, studies reveal that 66% of consumers would stop ordering from a company following a late delivery.

 

Consumers’ willingness to stop ordering from a company after just one late order forces businesses to adapt. Unforgiving consumer expectations can weigh on traditional solutions and force businesses to implement solutions like RFID and Fixed Industrial Scanners (FIS) that increase accuracy. While traditional barcoding solutions can read barcodes dependably, they can struggle to keep up with shifting consumer demands. When your workers have solutions that can’t keep up with consumer demands, your operation can suffer from:

  • Incomplete inventory visibility
  • Recurrent downtime from broken devices
  • Dissatisfied employees and lost customers

 

Solutions like RFID technology and FIS can differ from traditional data capture. Here are the specific benefits of each solution to help you consider which one is best for your business:

 

  1. Traditional barcoding for automated data recording – General-purpose scanning still improves operations since it mitigates errors associated with manual data entry. Traditional barcoding enables faster and more accurate information transfer to improve order movement and asset tracking, which ultimately save your organization time and money.
  2. RFID technology for dependable visibility in challenging environments – When processing multiple similar SKUs in less time, traditional data capture may not always be the suitable option for large-scale, busy distribution centers. RFID solutions are meant to quickly and accurately process large amounts of data in larger environments. Furthermore, RFID devices are purpose-built for rugged performance and support real-time locationing, making these solutions more beneficial for fast-paced environments where stock numbers change by the hour.
  3. Fixed Industrial Scanners for minimal touchpoints and disruptions – For a more robust, automated solution, Fixed Industrial Scanners (FIS) provide stable and accurate scanning in difficult places and challenging conditions, all without human participation. FIS is typically used on high-speed conveyor lines or in 24/7 operations to fully automate item scanning, verification and routing, optimize material flow, and redirect incorrect items. FIS also delivers immediate alerts of any inaccuracies and prevents misplaced or stolen products.

 

A business can meet tough customer demand by boosting its scanning capabilities with devices that offer durable designs, higher read rates, and versatile features. Learn about the difference between traditional data capture, RFID and FIS with Avalon.

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3 Ways to Lower Food Distribution Costs with Intelligent Product Identification

It is estimated that 40% of the entire US food supply is wasted every year due to visibility breakdowns in the storage and transportation process. Missed temperature changes, idle wait times, and overlooked expiration dates can all jeopardize product integrity while slipping under the radar, resulting in mass product recalls and contributing to approximately $161 billion lost in food waste annually. Between fluctuating shortages and increasing last-mile costs, distribution centers have no money -or time- to spend on excessive food waste.

 

That’s where Intelligent Labels Come In

 

As stated so many times before: Manual data entry leaves room for error. Despite this, many businesses still employ pen-and-paper systems due to its simplicity and low cost. On the other hand, the cost of recurrent recalls and damaged brand identity greatly outweigh the savings. To mitigate errors while lowering costs, intelligent labeling systems employing automated data capture and digitized reporting have been shown to increase accuracy up to 99.99%. At its core, a proper labeling system should include…

  • A printer that matches your throughput volume
  • A label that matches application and storage requirements
  • A scanner capable of reading your barcodes regardless of size and location

 

Once these factors are in place, companies can start taking a look at different label types to create a tailored solution. Regardless of which labels are selected, your identification system should aim at…

 

  1. Reducing errors before items progress through your facility – By tagging inventory straight at the receiving dock with long-lasting labels, you prevent early mis-identification and improper storage. Zebra’s Certified Consumables assist with this by leveraging strong adhesives tailored for the application and storage environment. RFID tags take this a step farther by enabling teams to track multiple identifiers with one tag, providing real-time verification through your mobile device.
  2. Accelerated identification with less wait time – Needless to say, automatic data capture is much quicker than manual logging; however, intelligent labels like Zebra’s freeze indicator labels provide at-a-glance temperature monitoring. Moreover, pairing intelligent labels with mobility solutions specifically built for cold chain operations like Zebra’s MC9300 help reduce costs and cycle times to increase sales and sustain easier data sharing even within the cold storage environment.
  3. Simplifies team communication by making track and trace easier – A smoother flow of information and less downtime play a critical role in simplifying track and trace operations. Intelligent labeling solutions streamline track and trace and equip your workers with important data they can use to respond to demands and each other faster. Furthermore, because data is stored digitally, audits become easier to perform, and data can be retrieved from anywhere in the facility between your secured devices.

 

While intelligent labeling sets a strong foundation for maximized visibility, it is only one part of the equation when it comes to lowering operating costs. Before selecting a label match, experts recommend meeting up with a labeling specialist to evaluate your environments and customize a solution that grows alongside your business. In addition to finding your best match, a proper workflow evaluation can also uncover more optimization areas hiding within your operation, giving you the upper hand to overcome challenges before they affect productivity.

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