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What Happens If Your Manufacturing Plant Compromises on Track-And-Trace?

As supply chains adapt to accommodate more unique stock-keeping-units (SKUs), tracking individual products from production to shipping has become more complex. Studies suggest that 8 in 10 manufacturing facilities struggle to capture and leverage meaningful data within their operations. Moreover, while a vast majority of decision-makers emphasize the importance of end-to-end traceability, 70% of businesses still operate with incomplete visibility into their vital operations. Lack of clear traceability ultimately contributes to:

  1. Wasted resources
  2. Sudden equipment failure
  3. Recurrent need for rework
  4. Failure to meet deadlines
  5. Unclear demand forecasting
  6. Broken customer loyalty
  7. Unmet compliance standards
  8. Jeopardized consumer safety

For the food industry, estimates show that improper visibility costs $10 million per recall, while other manufacturers in the pharmaceutical and automotive industries have seen upwards of 4.85 billion in losses and facility closures. Put simply, compromised track-and-trace can be devastating to a business.

Optimizing Traceability in the Manufacturing Plant

When trying to improve operational visibility, track-and-trace experts recommend defining required data within your operations. Although unique industries may track additional data points, a proficient traceability system should track:

  • Supplier lot numbers
  • Serial numbers
  • Storage status
  • Delivery dates
  • Raw materials used
  • Compliance notes

Tracking these data points for multiple SKUs has proven challenging, especially during high-demand seasons. Current labor shortages pose additional obstacles to ensuring every workflow is accounted for accurately. To fit seamlessly in today’s fast-paced operations, track-and-trace systems must allow quick adoption, leveraging user-friendly interfaces and streamlining workflows. Consequently, two types of technologies have become essential when developing end-to-end visibility.

  1. Digitized Barcode Scanning
    Automated data capture solutions eliminate the probability of errors and missed touchpoints. Furthermore, they allow workers to focus on more important tasks, minimizing stress from manual data input. Next-generation mobile computers and ultra-rugged tablets combine data capture with data processing, updating traceability logs as products move throughout the facility. These same devices can also be used for work-in-process reporting, push-to-talk communications, and cycle counting, thus consolidating multiple workflows through one easy-to-use terminal.For facilities with multiple conveyors and complex loading docks, businesses can fully automate quality checks with fixed industrial scanners, installed in high-influx areas. Scanned data can be transmitted to other IoT devices for immediate action, and into your reporting system for future use.
  2. Real-Time Locationing Systems
    Taking barcode scanning a step further, real-time locationing systems can consolidate several data points with fewer tags while also providing in-motion tracking. For example, RFID systems utilize wide-range antennas to locate stored inventory and finished goods. By tracking incoming materials in real-time, facilities may also optimize just-in-time delivery, reducing the risk of overstocking.However, RFID isn’t your only option when developing real-time locationing systems. Intelligent visibility software such as Zebra MotionWorks supports material replenishment systems, safety checklists, and call triggers to connect workers to crucial data anywhere in the four walls

How to Get Started

Before deploying any modernization solution, businesses should run a workflow evaluation to target blind spots and possible challenges. Once your goals and challenges are outlined, our teams work with you in consolidating workflows through technologies that support end-to-end visibility, including:

  • Flexible connectivity options
  • Seamless app integration with Android
  • Push-to-talk communications
  • Automated data capture and sharing

To learn more about Zebra’s in-stock devices, contact us here.

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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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How to Optimize Label Printing at a Lower Price Point

As warehouses continue to enhance order fulfillment, budgetary constraints remain a top concern alongside ease of integration. Between device procurement, software installation, and employee training, modernization costs can quickly grow out of control. Before integration, research estimates businesses already spend an average of nearly $3.7 billion in a 100-employee warehouse. Current labor shortages and demands have bolstered those expenses, forcing companies to compromise on cost and effectiveness.

 

Affordability Meets Adaptability

Establishing dependable product identification can lower the risks of misplacements, shipping errors, and overstocking. While integrating a label compatible with your facility is a great way to start, experts also recommend integrating an enterprise thermal printer built for continuous use. Zebra’s latest business printer, the ZT230, combines the required features of an industrial-grade device with intuitive functionality so you can:

  • Secure future scalability – Equipped with optional RFID printing and encoding, the ZT230 also allows you to tailor your connectivity preferences, so your teams can count on fast, crisp barcode printing anywhere in the warehouse. Moreover, its easy media loading further simplifies user training.
  • Enable remote troubleshooting – Zebra’s PrintDNA enables a series of productivity enhancers for customizable configurations and backward compatibility to make device management easier for your IT teams.
  • Integrate a printing station in a smaller space – Thanks to its small footprint and bi-fold door, the ZT230 doesn’t take up a lot of space, serving a variety of workspaces that previously relied more on smaller desktop models. Plus, its color-coded cues facilitate faster media loading with an easy-to-follow guide.
  • Protect data – Lastly, printer upgrades must value data security to prevent leaks and breaches. Zebra’s PrintSecure empowers you to tailor user access tiers and push security patches remotely to stop unauthorized user access.

 

Taking Affordability Farther with the GO Zebra Trade-In Program

As a Premier Zebra Solutions partner, Avalon simplifies the modernization journey with the GO Zebra Trade-In Program. Work alongside experienced teams to upgrade legacy printers from any manufacturer and get cash rebates per upgraded device. The entire process involves three simple steps:

  1. Purchase your affordable upgrade
  2. Submit a claim form within 90 days of the invoice date
  3. Trade in legacy devices for cash rebates

 

Before finalizing your choice, consider assessing your labeling solution to ensure your upgraded technology matches your needs. With a careful overview of your workflows and goals, implementation teams can adjust your solution for easier usage and better adaptability, two indispensable benefits that set you ahead of supply chain challenges.

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How to Assess if Your Printers are Built for Enterprise

When operating in high-volume workflows, a functional printer becomes the foundation for unbroken productivity. With 82% of warehouses reporting an increase in stock-keeping units, distribution centers expect greater challenges in maintaining speed and accuracy during the order fulfillment process. While adapting to persistent shortages and consumer demands, fulfillment teams have no time for breakdowns. Consequently, it is recommended that business assess their enterprise technology to prevent premature failure and downtime.

Zebra’s most recent Warehouse Vision Study suggests that by 2027, over 90% of warehouses will have implemented enterprise printing in their main workflows. As businesses procure hardware, consider the following questions to guide your search.

 

  1. Is the printhead developed for high-volume printing?

Consumer-grade and desktop printers are not suitable for long workhours and high printing volume. While cheaper upfront, businesses risk spending more on downtime and frequent IT visits since printheads cannot keep up with the workload. An enterprise printhead fit for high-volume warehousing should be able to handle the heat associated with thermal printing while also maintaining barcode legibility at faster speeds.

Moreover, in addition to searching for a suitable printhead, consider also printhead longevity since this will determine the possibility of future downtime. For example, Zebra’s enterprise printers proactively prevent downtime by offering free printheads for previously purchased devices. This empowers warehouses to plan replacements

 

  1. What barcode resolution will I need?

Furthermore, depending on the size of your barcodes, you may need a crisper barcode. For example, a small test-tube label needs a sharper barcode compared to a shelf-rack label which can be seen at a distance. Printheads must match the type of inventory or asset you plan to label to preserve future barcode legibility.

 

  1. Will I need an RFID encoder?

RFID is expected to overtake 8 in 10 warehouses by 2025. As businesses scramble to meet incoming RFID labeling requirements from major retailers, that figure is only expected to rise. Furthermore, RFID is a foundational technology to support numerous visibility solutions such as asset tracking, indoor locationing services, and predictive analytics.

Fortunately, printers like the ZT411 and ZT600 series offer optional RFID encoding alongside standard barcode printing, streamlining costs while securing scalability. Moreover, by spacing inlays closer, Zebra’s ZT600 uses fewer materials, reducing label costs.

 

  1. Are current printing stations creating bottlenecks?

Procuring new hardware creates a great opportunity to re-assess workflows and pinpoint bottlenecks. Printing stations have notoriously been behind bottlenecks and long travel times in the warehouse since workers need to walk and wait in line to print.

If multiple workflows require fast label printing, enterprise mobile printers may be a better solution than simply procuring another large industrial device. The ZQ630 delivers enterprise-grade durability and fast printing speeds to meet labeling requirements for on-the-go workers. On the other hand, if printing stations are still preferred, consider integrating a mobile printing station with power carts to reduce travel times.

 

  1. Can you protect printed data digitally?

In the current digital landscape, no industry can compromise on cybersecurity. Peripheral devices are prime targets for cyberattacks since they are less likely to be protected. Therefore, when searching for a new device, be sure it integrates with your current cybersecurity policies.

Applications like PrintSecure prevent unauthorized users from accessing your device while also protecting stored data from accidental WiFi and Bluetooth connections.

With these responses in mind, businesses can have a better grasp of the kind of device their operations need. For step-by-step assistance in assessing your printing needs, schedule a quick conversation with our automation teams.

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4 Ways to Optimize Your Barcode Printing Solution

For decades, barcode labels have safeguarded product identification and facilitated inventory movement down the supply chain. As warehouses become more dynamic to accommodate customer expectations and new compliance standards, effective barcode scanning remains essential to:

  • Verify the correct shipments are packed onto the correct truck
  • Prevent product spoilage or misplacements
  • Maintain accurate inventory counts to meet demands
  • Meet shipping deadlines on time

Furthermore, 82% of warehouses report an increase in stock-keeping units (SKUs) while studies show a 23% increase in shipping volume. With product quantity and differentiators steadily increasing, the time to optimize barcode printing is now.

Speed up Printing. Expand Printer Longevity. Ensure Successful Scans. Protect Printed Data.

Labels generally account for a small percentage of total operational costs, which means that even small adjustments can impact overall profitability. Below are a few ways warehouses have optimized barcode printing workflows.

  1. Match your printer to your throughput levels – Not every enterprise-grade printer is best suited for high-volume printing. Integrating the wrong printer into your space can initially save money, yet frequent printhead replacements and hardware damage create more unnecessary expenses after integration. While industrial printers can handle high-volume workflows and deliver 600dpi barcode resolution, smaller desktop printers like Zebra’s new ZD611 still deliver quality barcodes at faster speeds for smaller workspaces.
  2. Match label composition to your storage environment – Dust particles and extreme temperatures can harm printing performance, draining budgets in the long run. Fortunately, rugged industrial printers are made to withstand harsh environments with all-metal casings and durable printheads. Devices like the ZT600 Series Printers go a step further by combining rugged durability with a user-friendly touchscreen and media loading, accelerating deployment for faster productivity.
  3. Choose labels that protect the printhead – Inferior label quality damages printers over time by leaving behind debris and scratching the printhead. This creates gaps in the barcode that later hinder scanning. To prevent early printhead failure and jams, consider integrating quality labels like Zebra’s Certified Consumables. Labels with smoother surfaces and stronger adhesives are less likely to damage printheads and leave excessive debris in the printer, ultimately improving print quality and safeguarding printer longevity.
  4. Add printers to your cybersecurity initiatives – Lastly, while cybersecurity may seem far removed from barcode printing, peripheral devices are often targeted by cybercriminals since they are less likely to be protected. Data protection applications like PrintSecure block unauthorized users from viewing printed data while encrypting connections and enabling remote management.

Optimizing your barcode printing solution doesn’t have to be complicated. From label redesign to hardware upgrades, work alongside Avalon’s printer specialists to elevate operations and stay ahead of supply chain challenges. Contact us for a free workflow assessment to learn how you can get started.

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RFID checklist for smoother implementation

Real-time locationing has proven vital for almost every industry’s modernization plan. With 41% of shoppers citing shortages as the top obstacle keeping them from finalizing a purchase, distributors are turning to modernized inventory management solutions leveraging RFID to monitor shortages and predict demand. As major retailers like Walmart and Nordstrom demand RFID tracking for many everyday items, manufacturers and distribution centers cannot waste time on inefficient tracking systems.

 

Is RFID Right for You?

 

Not every business requires RFID tracking to establish dependable visibility. Consequently, before you investigate an RFID solution, experts recommend evaluating several components such as:

  1. Environmental challenges

High ceilings, metal racks and thick walls are just a few environmental challenges hindering RFID transformation. Unique locations such as cold storage or manufacturing facilities require durable technologies to withstand around-the-clock usage and extreme temperatures.

 

With a better grasp of the environmental challenges, technicians can recommend durable devices such as Zebra’s rugged fixed readers and handheld RFID scanners to ensure flawless scans anywhere in the facility.

 

  1. Current wave frequencies

Furthermore, assessing environmental challenges can also reveal potential interference from current technologies. Two-way radios, WiFi, and Bluetooth create interfering wavelengths. If left unchecked, interference can prevent data from reaching your teams on time, creating blind spots within your operations.

 

Depending on your workflow requirements, a different tracking system may be more compatible with your location to accommodate current technologies. Understanding your systems may also help evaluate if a passive or active RFID system is more beneficial.

 

  1. Type of inventory being tagged

Certain types of surfaces may be harder to tag, such as curved or metal objects. These can create more wave distortion, hindering successful reads. Fortunately, technological advancements are now bridging the gap between metal inventory and RFID tags.

 

New RFID on-metal tagging solutions empower manufacturers to track tools, fixtures and other metal parts without hindering read performance. Designed to print thicker tags, the ZT411 can deliver RFID encoded tags fit for metal surfaces through one user-friendly, industrial-grade device while also providing traditional RFID tags and barcodes for vital workflows.

 

  1. Estimated training time

Employees must become familiar with new devices, workflows, software and applications. The faster they learn, the less likely they will commit costly mistakes. Therefore, systems should employ easy-to-use technologies to lower training times.

 

While every new solution presents a learning curve, user-friendly operating systems like Android for Enterprise can help minimize training by consolidating workflows onto a familiar touchscreen interface. Moreover, Android’s open app ecosystem facilitates future app integration. Seamless integration ultimately preserves your solution’s scalability in the long run.

 

  1. Future configurations and updates

Current supply chain challenges are prime examples of how unforeseen changes can radically alter entire industries. That’s why scalability and flexibility should be ensured from the very beginning when possible. When you work alongside an experienced RFID solution provider, your operation can draw from their experience and prior successful implementations to create an adaptable plan that embraces future changes.

Once these factors are covered, businesses should have a better scope of their RFID implementation process.

 

Selecting a Viable Solution Provider

 

Whether you’re using an existing solution provider or evaluating a new one, you should understand that RFID implementations require an experienced, hands-on approach. Industry experts recommend evaluating current or future solution providers to make sure they offer:

  • Complete scalability of your whole system (not just hardware)
  • Software installation and reconfiguration
  • Long-term technical support
  • Rapid label development and delivery

There are numerous processes and workflows to evaluate when considering an RFID system for your operation.  For more information or location analysis, schedule a preliminary evaluation with one of our RFID specialists.

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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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There’s a New Tablet merging the boundaries between “consumer-grade” and “enterprise-ready”. Here’s What We Know:

When facing the stringent conditions of today’s modern warehouses, most operators agree that consumer-grade devices will only set back productivity. Prone to breakdowns and digitally rigid, personal devices cannot keep up with the kind of high-volume data processing common in today’s distribution centers. However, consumer-grade devices have retained user favor in supply chains due to their ease-of-use. Studies conducted by leading tech innovators have shown that 69% of IT decision makers see bring-your-own-device policies as a beneficial strategy to their operations. With labor turnover rates surpassing 40% in American distribution centers, familiar technologies prove beneficial by reducing training expenses and ensuring faster productivity. However, a lack of proper durability can increase costs by instigating…

  • Recurrent replacement and repair costs
  • Complex software and app integration processes
  • Compromised security parameters that endanger data safety

Modern-day technologies strive to combine familiar usability with robust functionalities, reducing operational costs. A prime example of this is Zebra’s newest Enterprise Tablet, the ET40/45. Like its predecessors, the new tablet streamlines push-to-talk capabilities, intense scanning, and real-time visibility within an Android interface. Upon a closer inspection, it’s easier to see the effects of today’s challenges on technological advancements.

Not like other tablets

Zebra’s previous tablets have always been crafted with durability and adaptability in mind to deliver versatile usage in different environments like distribution centers, cold storage units, and busy transportation teams. However, today’s push for faster productivity within dwindling labor pools have led tech players to leverage features such as:

  • 5G Connectivity and WiFi 6 – Dropped signals and dead zones halt productivity while isolating workers from receiving timely stock updates. To prevent communication gaps across the facility, newer, stronger connectivity options are now included in the new tablet.
  • Mobile POS options – As tablets now find their ways into the storefront in addition to inventory rooms and loading docks, the ET40/45 includes a mobile POS system to enable line busting through the same device used for inventory tracking and stock counting. This breaks down high adoption rates by streamlining crucial workflows through one standard device.
  • Multi-shift batteries – With the promise of same-day delivery comes longer work hours which demand longer lifecycles from your devices. As a result, Zebra’s new tablet incorporates hot-swappable batteries in its sleek design to deliver constant power across multiple shifts. Moreover, with the help of PowerPrecision, workers can spot failing and unhealthy batteries and remove them before they affect workflows.

Take a closer look into the ET40/45’s new highlights here.

As shortages continue to challenge the supply chain, automation solutions must fine the fine line between user-friendly and enterprise-ready. Compromise on either of these factors can lead to missed sales, damaged consumer trust, rising operations costs, or stressed workers. Consequently, experts still recommend assessing your current workflows with an automation specialist to verify your employees’ level of comfortability alongside current warehouse demands. In doing so, operations can best accommodate future demands with flexible solutions for continuous enterprise success.

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4 Realistic Expectations to Have from Today’s Modern Supply Chains

The last two years have drastically altered supply chain efficiency. The effects of nationwide lockdowns, global shortages, and international tensions have deepened a shared reliance on automated systems to stay ahead of mounting consumer demands and fulfillment challenges. However, amid recurrent and new obstacles, many businesses have shared positive workplace changes such as:

  • Improved worker conditions – Automated systems and enterprise robotics alleviate the stress placed on human workers while also requiring less muscle effort to meet demands.
  • Implemented easy technology – To truly be considered successful, a modernization solution should value user-friendliness to diminish training expenses.
  • Increased wages and bonuses – Around 45% of workers noted an increase in wages as warehouses and distribution centers sought to retain long-term employees.

Changes such as these can help foster more seamless workflows and satisfied employees. As new technologies are developed and integrated into the fast-moving supply chain, it is imperative to maintain realistic yet optimistic goals in the warehouse to correctly track KPIs overtime. Zebra’s newest 2027 Warehouse Vision Study showcases four of the most common goals today’s warehouse managers:

  1. Improving individual worker productivity – It has been estimated that nearly a quarter of warehouse operations were managed through paper-based systems. This means that workers had to spend a bulk of time updating reports, verifying stock counts, and imputing updates manually at the risk of entering the wrong data.
  2. Streamlining workflows in a standardized fashion – As fulfillment tasks became more complex with same-day shipping, higher return rates, and direct-to-customer transactions, businesses needed a way to ensure workflows were accurately tracked from door to dock. Consequently, 41% of companies began to optimize mobility in 2022 to ensure new and permanent workers stay organized through one trackable workflow managed through their handheld device.
  3. Maximizing asset visibility – From mobile devices to centralized printing stations, your warehouse assets play an intricate role in sustaining productivity across the warehouse. Consequently, maintaining device availability through real-time asset tracking systems has become a goal of nearly 70% of warehouses worldwide. Clear operational visibility further empowers warehouses to prepare for challenging demands since decision-makers have a better picture of the resources available to them at a moment’s notice.
  4. Collecting and leveraging data via intelligent automation – The prevalence of sudden changes has created a need for multiple data capturing systems to ensure nothing is ever missed. Therefore, systems featuring technologies like autonomous robots, fixed industrial scanners, and even RFID portals have proven beneficial to drive automated decision making based on real-time insights. This means warehouses can ensure the correct orders and reaching the correct customers, stock quantities are current, and workers receive the assistance they need when and where they need it.

How to make sure these goals are met

E-commerce transactions continues to be one of the largest forces behind modernization, impacting nine out of 10 warehouses by increasing shipping volume. To meet expectations within a dynamic omnichannel ecosystem, experts recommend…

  • Assessing warehouse space to target challenges in the RFID implementation process such as high ceilings, dense walls, etc.
  • Supporting migration plans to adaptable operating systems like Android to make sure new updates and patches are accommodated into current workflows
  • Consolidating workflows into wearable devices to alleviate weight and pressures from your workers while cutting back on management plans for multiple devices.

Navigating through several modernization challenges becomes simpler with a team at your side. To get a closer look into how supply challenges are continuing to affect modernizing warehouses, reach out to our modernization specialists and approach optimization with a confident yet adaptable strategy.

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