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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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This is How One Smart Label Improves Food Safety.

Research from Zebra’s most recent Food Safety Study suggests that only 2 in 10 consumers actually trust food manufacturers and distributors to ensure complete food safety within their operations. Inaccurate track-and-trace systems have played an integral part in major recalls, foodborne illnesses, and crippled brand identities over the years, contributing to the requirements for dependable visibility solutions. Future-forward systems leveraging RFID and wireless data have risen in popularity, spearheading many modernized track-and-trace solutions; however, for growing businesses seeking to place a strategic focus on food safety, these large-scale changes may be more difficult to achieve due to the time and costs involved to implement.

 

While modernized track-and-trace systems benefit businesses of all sizes, there are simpler, supporting solutions to help improve visibility without deploying a completely new system. Developed to react to shifting temperatures, Zebra’s temperature-indicator labels provide at-a-glance insights, so distributors and manufacturers can track temperature exposure and ensure product quality.

 

How They Work

 

Engineered with temperature-sensitive technology, Zebra’s intelligent indicator labels react to the environment and change colors depending on heat or cold exposure. Plus, TransTracker indicators contain strong adhesives to remain applied during cold chain transport, ensuring product integrity once it leaves the facility.

 

Temperature indicator labels are not limited solely to distribution operations. Manufacturers and retailers have also leveraged freshness indicators on perishable items, which can be easily interpreted by shoppers directly at the storefront. Businesses have reported up to 30% more sales when using freshness indicators, which can influence purchase decisions on the spot. Compared to larger systems, freshness indicator labels are relatively inexpensive and easy to use since they are read by both businesses and consumers alike.

 

Is Temperature Sensing Enough?

 

At-a-glance temperature checks empower teams to spot potential spoilage and prevent illnesses, and when it comes to creating a proactive plan, they serve as a great start.  However, a more robust plan may be needed if your facility still experiences…

  • Idle shipments waiting to be refrigerated at the loading dock
  • Wrong shipments sent to your customers
  • Time-consuming audits
  • Complex and/or inaccurate product locationing
  • Recalls that force a complete productivity halt

Because these issues compromise product integrity, they may require a more sophisticated track-and-trace solution that can view and report on all product movement in real-time.

Whether you’re just starting with food traceability or your current product tracking system needs modernization, set up a preliminary evaluation with one of our cold chain specialists.  Learn how you can build or update a food safety solution that grows with your operations without overextending your budget.

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Optimizing Cold Storage: How Warehouses are preparing for the Food Safety Modernization Act Update

The U.S Food and Drug Department (FDA) estimates that nearly 1 in 6 Americans suffer from a foodborne illness per year, resulting in about 128,000 hospitalizations and 3,000 deaths. Needless to say, there is no place for compromise within food safety parameters. Studies show that a mere 20% of consumers completely trust manufacturers to ensure proper safety measurements, and 60% avoid businesses responsible for even one illness incident. To combat illnesses and restore buyer confidence, the FDA has now shifted its focus to proactively preventing illnesses from festering within the manufacturing and distribution process as opposed to simply targeting system breakdowns. Per the updated Food Safety Modernization Act, supply chains will be expected to enhance track-and-trace systems to record and store data for up to 2 years by November of 2022. Data should be retrievable within 24 hours to enable quick farm-to-table traceability. To achieve this, businesses are encouraged to strengthen the following pillars of dependable traceability:

  1. Monitor growing/manufacturing process to ensure only verified ingredients are used.

The FDA’s Food Traceability List allows manufacturers to prioritize real-time visibility for at-risk foods within the very first steps of production. Freezer-ready technologies like the MC9300 can help streamline inventory control by combining data capture and processing onto one digital platform. Rugged labels should also be employed to preserve barcode readability, so ingredients can be verified during production.

 

        2. Optimize communication at the receiving dock, so products are not idly waiting in dangerous temperatures.

Just-in-time replenishment has become evermore commonplace in most distribution centers, which means teams must be able to effectively communicate when items arrive to prevent spoilage or inventory loss. Whether it be through automatic alerts via handhelds or group calls through a push-to-talk system, team communication at the loading dock ensures food safety measures are carried out the moment products arrive.

 

        3. Track handling process for at-risk foods such as shellfish, fruit, leafy greens, eggs, cheese, and ready-to-eat salads.

For real-time inventory management, RFID and locationing systems prove to be indispensable. Because RFID tags can hold as many as 40 different codes per tag, RFID systems empower teams to track multiple status points for each product at once to see if they were handled properly.  Automated data recording further simplifies future auditing since data can be retrieved automatically with less risks for error.

 

        4. Notify delivery teams and other members in the supply chain of shipping timeframes and inventory status.

These FDA changes have placed greater responsibility on the entire supply chain, which means proper tracking must extend beyond the four walls. This is where Bluetooth-powered technologies like Zebra’s Electric Temperature Monitoring Sensors prove highly beneficial as businesses can track transportation temperatures in real-time to prevent spoilage.

 

Regardless of how you choose to approach food safety, one thing is certain: Visibility is key.  Whether it be through enhanced group communication or real-time inventory tracking, businesses must quickly adopt to establish proper food safety standards. For more information on how you can optimize your workflows to comply with the Food Safety Modernization Act, contact our automation specialists here.

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Where does Zebra’s new WS50 fit?

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Zebra’s newest wearable computer has gained much attention for being the world’s smallest wrist-mounted computer. Lightweight and fully ergonomic, the device replicates many functions currently conducted by larger handheld computers, yet it brings unique benefits to specific applications. To best harness its features, businesses seeking to implement the WS50 should consider its top use cases. Developed to simplify data capture and sharing, the WS50 has seen the most proficiency in:

  • Retail markdowns – Shifts in demands can cause rapid price changes over shorter periods of time. Team members equipped with unbreakable data accessibility through wearable devices can quickly scan and verify inventory information without extra bulky devices or paper stock counts.
  • Task management – Operating with smaller workforces under constant labor turnover, warehouse teams require real-time task management that can prioritize in-need operations in real-time based on current workforce size. The WS50’s flexible connectivity features allows teams to update task assignments on the go for less unbroken productivity.
  • Warehouse order fulfillment – Encompassing over 50% of labor efforts, order fulfillment is the foundation of successful distribution. With customers demanding consistent accuracy rates within smaller delivery timeframes, automated picking, sorting, and loading hastens the fulfillment process while increasing throughput without overburdening your workforce. Mobile computing also curbs unnecessary travel since workers no longer need to check in with a centralized desktop to update reports.
  • Accuracy verification – Lastly, whether in the warehouse, in a storefront, or even in non-traditional settings such as food service and hospitality, the WS50’s intelligent scan engine provides higher accuracy rates by verifying product data without paper-based systems.

 

How is this different from a traditional handheld computer?

While the WS50 shares many similarities with leading mobile devices, its small size and wearable capabilities increase responsiveness since workers can be expected to be wearing their devices. Wearable technologies have consistently shown to be easier to adopt since they leverage natural human movement, ultimately empowering teams to…

  1. Cut down device management costs since the device already fulfills the role of a ring scanner
  2. Further connect teams through embedded push-to-talk features on a wearable band
  3. Customize mounting and applications to create a tailored wearable solution that’s easy to grasp by new hires.

 

The road to effective modernization can take many forms. While a hardware upgrade can be essential, sustainable efficiency is developed with tested expertise and solution support. To translate the benefits of the WS50 into your workflows, consider meeting up with one of our automation experts to pinpoint bottlenecks and optimization opportunities in your workflows.

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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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Warehouses are not exempt from the Circular Economy. Here’s why:

Gone are the days where single-use products are the norm. Standing amongst several customer demands, sustainability has been an initiative driving changes across the supply chain. While there are many reasons behind this, a few notable factors fueling change in warehouses are:

  • Shared belief among decision-makers – Recent studies show that over 90% of chief executives see sustainability as a top priority to ensure future success.
  • Warehouse packaging contributes to a great deal of waste in landfills – The Environmental Protection Agency (EPA) estimates that container and packaging have continued to as much as 82.2 million tons in solid waste, of which 37% was landfilled.  
  • Customers believe brands should take corporate responsibility – Over 75% of today’s consumers are seeking brands that focus on taking better care of the planet in addition to more personalized and meaningful experiences.
  • Material shortages leave little room for unnecessary waste – Supply shortages for raw materials have impacted manufacturers by lowering production rates, making reverse logistics crucial to expand product availability since returned items could be resold to help prevent out-of-stocks. 

3 Ways to Prioritize Sustainable Warehousing 

As technology continues to advance, more sustainable solutions continue to develop. While there are many large-scale changes available, Avalon continues to push small-scale changes alongside bigger implementations for greater savings in a smaller carbon footprint. A few of these changes involve:

  1. Maximizing the use of reusable containers – To reduce the number of disposed packaging and pallets, distribution centers have turned to reusable containers and removable labels such as the 8000D Dissolvable Labels to properly identify products without slowing operations as containers need to be re-identified. 
  2. Streamlining inventory control through a shareable WMS – Studies show that a properly functioning WMS can increase inventory by upwards to 30%, minimizing risks of out-of-stocks and overstocking. Moreover, a digitized WMS removes the need for paper-based reporting, further reducing waste while maximizing data accuracy and accelerating easy data sharing across the supply chain.   
  3. Choosing an upgrade path that integrates recycling – When outlining a modernization strategy, the fate of your legacy and decommissioned devices should be a crucial factor to avoid contributing to more e-waste.  As a Zebra Premier Solution Partner, Avalon works alongside businesses to facilitate eco-friendly modernization with the GO Zebra Trade-In Program. By accepting devices from any manufacturer, Zebra upgrades ensure traded devices are properly recycled and destroyed without adding to landfills.  

Sustainable modernization is not a contradiction. Reach out to our team to explore further steps your warehouse can take in creating an eco-friendly optimization strategy that still embraces the latest edge in innovation.

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Why pick a touch-computer over a standard handheld device?

Mobile devices have become the foundation of effective modernization since they keep crucial data and connectivity right at your fingertips. They also successfully bridge the gap between teams within a supply chain, automating data capture and sharing through a digital interface. Consequently, handheld devices have become popular across multiple industries, from high-demand manufacturing plants to family-owned storefronts. As customer demands for faster and more accurate fulfillment increased, mobile devices have been enhanced to provide flexible connectivity options, consolidate disparate workflows, and last beyond the standard 8-hour shift. 

Despite these enhancements, traditional handheld computers and scanners may still be bulky for workers traveling between different locations. For more on-the-go teams, handheld devices must prioritize automated intelligence alongside ease-of-use and ergonomics. 

That’s where touch computers come in.

Today’s cellphones have shaped the expectations for easy-to-use technologies. In as little as zero clicks –thanks to voice commands– users can access files, navigate the web, and send messages. Similarly, Zebra’s touch-computers combine the intuitiveness of consumer-grade touchscreens with the enterprise functionality of traditional rugged handhelds. The result looks a little like this:

Zebra’s latest TC52AX touch-computer is a prime example of user-friendly handheld mobility; however, it is not the only option available. Because different workloads may require different levels of functionality, experts recommend assessing your options with the following three considerations:

  1. Will scanning capabilities be needed? – While some touch-computers can capture data up to 50ft away, not every workflow requires this. For example, while the TC20/26 may not offer the widest scanning range, it makes up for the difference in long-lasting battery power that surpasses double shifts. 
  2. How far will workers travel? – When it comes to communication outside of the four walls, devices like Zebra’s TC7x offer greater connectivity flexibility, providing secured communication through cellular, 5G, LTE, WiFi, and more. 
  3. Will you be adding additional devices? – From wearable devices like ring scanners and headsets to mobile printers, additional devices will impact worker mobility and comfort. Lightweight devices streamlining multiple workflows benefit workers by minimizing strain and connecting workflows simultaneously. 

To help you answer these questions, Avalon recommends scheduling a workflow assessment to select a device that best adapts to your operation. Once a device is selected, automation experts can also assist in procuring and preparing devices for integration through the GO Zebra Trade-In Program for cost-effective and intelligent modernization.

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