The challenge of delivering e-commerce, direct-to-consumer orders has introduced new levels of complexity in fulfillment centers. Wide variances in order profiles, the proliferation of SKUs and items with varying pick velocities are all highlighting the importance of effective order consolidation processes. Although many fulfillment centers are deploying automated systems in strategic areas of the facility to improve picking, sortation and putting efficiencies, order consolidation - which requires an effective way to aggregate this demand from disparate areas of the facility - often suffers. Regardless of the picking and sortation method used, put walls are becoming an indispensable tool for adapting to modern fulfillment demands and providing efficient order consolidation.
The premise behind put wall utilization is to bring together items gathered from disparate picking activities into one place. By consolidating this demand at one or more put walls throughout the facility, fulfillment centers see efficiency gains in upstream picking processes and, more importantly, increases in order fulfillment throughput and accuracy.
Traditional put walls are designed with fixed compartment sizes (or cubbies) and typically rely on lights, voice or RF technology to automate the confirmation process as an operator puts items into cubbies for specific orders. While effective, these fixed put wall designs may limit a retailer's ability to adapt these cubby sizes in response to changing order and product profiles, thus resulting in poor space utilization in the warehouse. The recent introduction of modular put wall designs, which allow the warehouse manager to change the configuration of cubby sizes (hardware) and light confirmation sequences (software) - provides the flexibility and space utilization that high-density fulfillment centers demand.
Our next On The Move webinar, titled, "Concerns about changing order profiles? 'Put' them to rest!" will explore these concepts and the increasing use of put walls in omnichannel fulfillment centers. The webinar will take place on Thursday, April 27, 2 p.m. EDT / 11 a.m. PDT, and be presented by Doug Mefford, product manager for order fulfillment with Intelligrated Software. With two decades of hands-on experience in driving throughput and accuracy in warehouse workflows and automation technologies, Doug will explain how put walls are improving order fulfillment productivity. Attendees will learn:
- The emerging role of the put wall and its order consolidation benefits
- Several key scenarios where put walls are effective
- How to recognize when order volume thresholds warrant put wall integration
- Why the need for flexibility led to new put wall hardware and software that enables user-driven customization
To learn more about put wall best practices and tips for integrating them in order fulfillment operations, register now for our upcoming On The Move webinar on Thursday, April 27, 2 p.m. EDT / 11 a.m. PDT.
The benefits of voice technology in the warehouse are indisputable. From increased throughput and accuracy to reductions in training time, errors and employee turnover, voice solutions are becoming an essential asset in the DC operations manager's toolkit. But what if they could extend those benefits even further, and in doing so create a performance-driven culture of excellence that addresses today's rising labor challenges? By pairing voice with labor management software (LMS), they can.
It's estimated that order fulfillment and replenishment activities account for up to 65 percent of total warehouse expenses. And with the ever-increasing complexities of omnichannel and direct-to-order fulfillment, some say this is a conservative estimate. Couple that with rising labor costs, changing workforce demographics, and the difficulty attracting and retaining qualified employees, and the importance effective labor management becomes even more imperative. It's no surprise then that many businesses are combining LMS software with their voice systems to maximize employee productivity and DC performance. Here are five ways LMS helps achieve these goals:
1. Increase employee engagement: LMS helps employees connect their individual performance with the company's larger objectives to help them feel empowered and understand their impact on their employer's overall success. This transparency also opens the lines of communication between management and employees to create a continuous improvement loop.
2. Incentivize performance: Both monetary and non-monetary incentive programs have proved extremely effective in driving performance. LMS allows companies to tune their incentives so that every 50¢ increase paid in incentives nets the company a $1 increase in throughput.
3. Improve labor planning: During peak periods, operations managers often overstaff up to 25 percent to ensure all orders are fulfilled. Across different areas of the facility and a larger DC network, this overstaffing quickly adds up. LMS allows managers to pull up historical data to develop more accurate staffing models during peak periods, even when sometimes eliminating the need for additional resources.
4. Adapt to the unexpected: Inevitably, things will not go as planned. With real-time execution monitoring, LMS helps managers quickly adapt to increases in demand before service level agreements are impacted.
5. Drive measurable performance improvements: Returns on an LMS investment depend on where DCs currently are in their performance optimization continuum. But, through the processes of developing labor standards and establishing performance incentives, a typical LMS implementation drives anywhere from 25-60 percent average throughput gains - with some statistical outliers even exceeding 100 percent improvements.
Intelligrated's GoalPost® LMS has been successfully deployed on countless occasions - in combination with our Voice Solutions or other voice systems - to enable these benefits in the warehouse. While robust data and reporting are at the core of our LMS offering, it's the tangible transformation of the workplace culture that is the true measurement of success. If you're ready to instill a culture of accountability, reward and retain your best employees, and realize true throughput gains, consider the benefits labor management software can bring to your operations.
Predicting the future of supply chain management can be a fool's game. Media outlets and trade associations alike hail big data, robotic solutions, the cloud and predictive analytics as the disruptive technologies and trends set to meet supply chain challenges of the future. But what about the here and now? Of the technologies pegged to cause disruption or drive competitive advantage in the 2016 MHI Annual Industry Report, two have already made a bigger impact than previously expected: robotics and automation, and driverless vehicles and drones.
Since their inception in manufacturing environments in 1954, robotics have delivered real-world results, helping companies optimize processes, improve efficiency and create a more flexible experience for workers. As today's operations battle SKU proliferation, managing a wide range of product and packaging types, the flexibility and adaptability of robotic solutions offer the right attributes to meet more dynamic downstream demand.
Case in point: Kelly-Moore Paints™ installed an Alvey robotics palletizing system that resulted in trading high employee turnover and injury risk of manual palletizing for the speed and reliability of automation. Prior to installing an end-of-line robotic palletizer, Kelly-Moore employees were hand-palletizing products weighing up to 70 pounds, leading to production flow inefficiencies. Intelligrated's robotic palletizing system now enables the line to run at an even pace throughout the day by eliminating the breaks required by heavy-lifting in the manual process. Additional efficiencies of the robotic palletizers came through faster line changeovers, which now take only nine minutes compared to 45 minutes with the old system.
But this technology can go much further than robotic palletizers in the warehouse or manufacturing facility. There are flexible, reliable robotic solutions to increase line speed, workplace safety and order accuracy in the following applications:
- Robotic case packing and unpacking
- Robotic picking
- Robotic depalletizing
- Robotic tote handling
In the long-term, robotic integration and other industrial automation increases productivity and creates safer work environments. And with the increasing demands of e-commerce fulfillment, new robotic solutions continue to emerge.
ProMat and Automate 2017 are quickly approaching, coming to McCormick Place in Chicago April 3-6. To get the most out of the Windy City and these action-packed events, take a look at this top-10 list of can’t-miss activities.
10. Treat yourself at the Magnificent Mile
Find yourself with some down time? Chicago has hundreds of fancy stores in a one-mile radius. ProMat and Automate offer a special “Show Your Badge” program at Bloomingdale's Chicago flagship store – present a show badge to the Michigan Avenue third-floor visitors center during the week to receive a 15 percent savings certificate.
9. Recharge at The HUB
Booth #2646 – the center of the show floor – is set up as a dedicated social networking lounge. Attendees can catch the latest buzz about the event on Twitter (use #ProMatShow), LinkedIn, the MHI blog and the ProMat 2017 YouTube channel. It also offers wireless internet for checking email and networking with other attendees.
8. Grab some deep dish!
What trip to Chicago is complete without deep dish pizza? For the extra layers of cheese, chunky tomato sauce and buttery crust, check out these go-to deep dish pizza spots:
Pizzeria Uno: Chicago's famous deep-dish pizza was born here in 1943.
Giordano's: The stuffed pizza here is even thicker than deep-dish style
Gino's East: This spot became an instant legend with locals, national celebrities and visitors from around the world.
7. Cross the border...to Automate!
Just across the hall from ProMat is Automate, the broadest automation solutions event in North America, featuring the latest in cutting-edge robotics, vision, motion control and related technologies. The same badge grants admission to both shows.
Visit Automate booth #1616
The Intelligrated Automate booth features a fully automated and integrated each-picking demonstration. The solution includes a two-level AS/RS shuttle, vertical conveyor and advanced robotics able to pick and place individual items typical of e-commerce fulfillment environments.
6. Visit the world-famous fossil known as "SUE"
Science rules at the three great institutions that make up Chicago’s lakefront Museum Campus. Sue is the centerpiece of the Field Museum’s collection – she’s the largest, most complete T. Rex ever found. After a selfie with Sue, wander over to the mummies and other artifacts (open daily from 9 a.m. to 5 p.m.).
5. Check out these ProMat keynote addresses from the sharpest minds in the industry
Monday: Building supply chain sustainability for competitive advantage: Lessons learned from leaders in innovative facility design
Best selling author and advisor to Fortune 500 companies, Andrew Winston leads a panel discussion on using sustainability strategy to build more profitable, resilient operations and supply chains.
Tuesday: Industry 4.0 - How intelligent machines are transforming supply chains
Markus Lorenz, partner and managing director, The Boston Consulting Group, will explore the many ways this revolution impacts material handling, the supply chain, the economy and what kinds of new jobs it will create.
Wednesday: The power of magic: Know your customer and where they are going
NBA legend, two-time Hall of Famer and Olympic Gold Medalist, Earvin “Magic” Johnson sits down with DC Velocity group editorial director Mitch Mac Donald to discuss the secrets to his business and personal success.
4. Tweet / Instagram a picture at 'the bean' in Millennium Park
The bean, officially named Cloud Gate, is the iconic reflective sculpture at the center of Millennium Park. Inspired by liquid mercury, the sculpture is among the largest of its kind in the world, measuring 66-feet long by 33-feet high. Don’t forget to include a fun hashtag such as #SeenAtTheBean.
3. "Party on" at industry night with comedian Dana Carvey
On Wednesday, April 5, comedian Dana Carvey will headline ProMat’s industry night. The event includes live music, food, drinks and a chance to win an all-expenses paid bucket list vacation for four. A portion of ticket sales are donated to the Material Handling Education Foundation, Inc. (MHEFI).
2. Attend on-floor seminars for the latest trends and innovations
Both shows host a plethora of interesting on-floor seminars. Here are four favorites that feature Intelligrated input:
April 3 at 3:45 p.m. - Lifecycle Management - Maximize your ROI
Learn the key components of a lifecycle management program and strategies to keep employees engaged, trained and safe
Presented by Dave Trice, senior director, LSS business development and Doug Bach, LSS sales manager
April 4 at 11:15 a.m. - CSS of MHI Presents: Sortation - Directing Product Traffic
Learn about sortation conveyors of all levels and take a deeper look into loop sorters, a unique solution for all types of product (even those difficult to convey on other sorters)
Presented by Satyen Pathak, senior product manager
April 4 at noon - 10 Steps to Improve Operational Efficiency
Hear about common challenges of today's fulfillment operations and learn 10 steps companies can take to improve operational efficiency
Presented by Chris Arnold, vice president, solutions development and Mark Steinkamp, director, solutions development
April 5 at 3 p.m. - Automating warehousing and logistics operations (Automate)
Learn how advanced robotic technologies can solve order fulfillment challenges
Presented by Matt Wicks, vice president, product development, manufacturing systems
1. Visit the Intelligrated booth!
At ProMat booth #S2003, Intelligrated delivers the broadest range of industry-leading sortation equipment, put- and pick-to-light fulfillment technologies, labor management software and Lifecycle Support Services.
Attend in-booth presentations - and win an Apple Watch!
Three topics, three times daily, the first three days at the show, presented every hour, on the hour, from 11 a.m. to 4 p.m.
- Be proactive! Maximize your system’s uptime
- Sort it out! E-commerce challenges and sortation
- WES: Real-time warehouse decisions. On-time deliveries.
Those who attend a presentation and get their badge scanned are entered into a drawing to win an Apple watch. The drawing takes place on Wednesday at the close of the show – attendees need not be present at the drawing to win.
It’s all happening at booth #S-2003, located immediately to the right as you enter the south hall. Don’t miss it!
To keep pace with consumer expectations and enable direct-to-consumer delivery, retailers and manufacturers are rapidly evolving their distribution center strategies. Many are migrating their fulfillment operations toward mega-cities and high-population centers to enable on-time delivery, making the efficiency of these DCs more important than ever. But things are also evolving inside the four walls to maximize the available space and optimize product and employee workflows. This "warehousing compression" strategy requires better utilization of vertical spaces and new automation equipment to support this upward trend in high-density facilities.
Some innovative approaches to vertical expansion include facility upgrades to include mezzanines, multiple floors and, most importantly, vertical conveyors to facilitate the movement of product throughout these various levels. Whether it's footprint, flexibility, throughput or ergonomic consideration, each facility has different requirements for its vertical conveyors.
In Intelligrated's most recent On The Move webinar titled, "Vertical solutions: elevating your products to the next level," I discussed the available vertical conveyor options to meet these challenges. While the concept of vertical conveyance is relatively simple - moving product in a carton or tote to a different level in the warehouse - the variety of options to accomplish this can address varying degrees of process complexity. To select the best option for your operations, it's important to understand the pros and cons of each option.
As I presented in the webinar, vertical conveyors fall into four basic categories:
Continuous flow - Comprised of either incline or spiral options, continuous flow conveyors feature belt or motor-driven rollers and offer simple control systems. While incline conveyors provide high throughput rates, they are limited to single entry and exit points, and take up a lot of floor space. Similarly, spiral conveyors also provide high throughput rates and a relatively large footprint, but offer multiple entry and exit points.
Suspended shelf - As the name implies, suspended shelf conveyors employ a vertical shelf design to achieve multiple product elevations. Continuous suspended shelf options utilize a simple control system, provide single entry and exit points, offer medium throughput rates and still require medium to large space allotments.
Indexing suspended shelf - These servo-control systems have similar characteristics to suspended shelf conveyors while adding the benefits of multiple entry and exit points, and vertical merging and sorting.
Reciprocating conveyor - Vertical reciprocating conveyors (VRC) offer maximum flexibility in conveyor / shelving configurations and take up very little floor space. Also driven by a servo-control system, VRCs integrate with single-, double- or triple-zone conveyors; offer over- or under-conveyor configurations; and can be utilized in speciality zones such as transfers or turntables to deliver product to the most ergonomic position for workers. Since the shelf returns to the start position for product induction, VRCs operate at lower throughput rates. Regardless, the flexibility and small footprint of VRCs are making it an increasingly popular option.
Ultimately, selecting a vertical conveyor depends on your specific business objectives. To learn more about the possibilities of vertical conveyance and better understand which option is right for you, please view this webinar on our website.