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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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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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How are companies rebuilding consumer trust? The Answer is Traceability

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One of the biggest challenges set to impact supply chains in the years to come is reestablishing customer trust. The coronavirus pandemic simply enhanced previous concerns many customers already had surrounding product fabrication, compliance, order accuracy, etc. From retail goods to manufacturing parts, studies show consumers are more and more skeptical of supply chains, increasing the demand for transparent traceability to soothe worries such as: 

  • Brand’s ability to ensure safety – Only 35% of consumers actually believe the food industry is technologically capable of ensuring proper safety guidelines.
  • Delayed order tracking – Since 2017, it’s been estimated that over 90% of customers expect to be able to track their orders from start to finish, preferably in real-time.

  • Seamless returns in the event of inaccurate orders – At least 96% of customers admit to returning to a business that offers easy returns, which means complicated reverse logistics can deter over half of prospective clients.

Whether you run a business-to-business or a business-to-customer operation, no company is immune to disruptions, and these disruptions -whether via a cyberattack or a sudden spike in demand- can either weaken or strengthen your brand’s identity. While disruptions can happen at any given moment, traceability solutions offer preventive measures to protect consumer trust and minimize damage. Below are 5 ways companies are re-establishing trust in the New Normal: 

  1. Verified contact tracing and social distancing – Needless to say, health concerns are far from gone and will most likely be around for a while. That’s why contact tracing solutions have remained crucial to prevent mass germ spread while targeting potential infections without completely halting productivity. Efficient systems like Zebra’s MotionWorks Proximity have recorded a 75% reduction in proximity events within one week of deployment all while providing an easy-to-follow traceability system between events for scheduled alerts.

  2. Real-time notifications – Time is now more than money. It is also safety and possibly your first defense against sudden changes. Real-time visibility, whether through RFID technology or high-speed WiFi connectivity, equips your workforce with valuable updates as they happen, allowing your teams to respond proactively to change. 

  3. Dependable data security – To mitigate cyberthreats, businesses continue to migrate to supported operating systems such as Android. Zebra’s fortified Android goes a step further by embedding automatic OS updates, government-grade encryption, two-factor authentication, and customizable security parameters along with recurrent security patches. 

  4. Long-range networking to connect customers and field teams – To enable tracking for field teams, long-range and flexible networking systems must survive in difficult environments at all times. Not only does this allow customers to track orders, but it also connects field teams to any real-time updates and changes in the warehouse. 

  5. More safety stock – Depending on inventory type, increasing safety stock may be helpful to prevent stockouts during spikes in demand. To efficiently increase stock quantity without losing track of in-house inventory, we recommend adding automated data capture technology that connects to your inventory management system, along with easy-to-ready durable labels.

To see how you can adapt any of these methods into your business, reach out to our modernization specialists and see how you can set your operations on a firm footing to face 2021’s new and recurrent challenges. 

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