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Top 10 Solutions for Common Warehouse Problems

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Top 10 Solutions for Common Warehouse Problems

Warehouse Engineers attended the Modex Conference looking for low-cost solutions to improve warehouse operations. As a previous warehouse manager, I understand traveling isn’t always an option because you have to get orders out the door. No reason to fret, Warehouse Engineers has you covered with 10 solutions to common warehouse problems.

Problem 1: Cycle counts

We’ve all been there… the quarterly cycle count or worse, the full annual. Ware eliminates the cycle counting dilemma. Yes, that’s right, Ware deploys fleets of drones, powered by machine learning, to perform cycle counts. Ware creates the software and analytics that lets the drones do the work, saving time and money.

Problem 2: Tracing orders

Ever had an order delayed by the rail or carrier?

Me!!! I’ve been on the phone with the carrier asking where is my order?

Pallet Alliance developed a platform to track individual pallets from end to end of the supply chain with IoT connectivity. Intellipallets integrate with existing wooden pallets providing efficient tracking of shipments. Once the pallets become “intelligent” they provide information like transit location or stationary time. Now you will know when your order is stuck in a rail yard.

Problem 3: BOL Paperwork

Why does the customer call for the BOL that you can’t seem to find?

BOLs are a necessary evil. You must get the driver to sign for the order, then store the order for years. The process creates so much paperwork, and it’s even harder to track individual BOLs. I hate when the customer calls for a BOL from 3 months ago. The smart people at SMART BOL developed an automated solution for bill of lading signing and document retention. Yes, there’s an app for drivers to sign the BOL and the signature magically goes into the cloud.

Problem 4: Communication Boards

I’ve struggled with outlining a whiteboard for daily huddles. The magnets are not straight, the markers start to fade. Sometimes I spent more time preparing for the meeting than the actual meeting itself. Visual Workplace is a source for Lean & 5S Supplies. They have great templates for KPI Tracking and daily huddles. Visual Workplace can also print dry erase board overlays for kaizen events and root cause analysis.

Problem 5: Workstations

We all know the value of 5S, “a place for everything, and everything in its place.” But what if you don’t have a place for everything? Literally, while you are setting tools in order, you are missing a place for a tool. With PioneerIWS, you can easily build a custom workflow to meet your needs. Their Flexturs can be transformed into mobile workstations, shelves, and packaging stations. Setting and Sustaining workstations are a lot easier with PioneerIWS.

Problem 6: Shifted Rail Cars

Ever been nervous about opening a box car?

I’ve been there, crossing my fingers hoping that the pallets are still upright.

Of course, the pallets have shifted and spilled over. Have you ever seen a rail car full of spilled tomato paste, yuck! Shifted cars are a no-win for everyone involved. Filing a claim with the rail line is so difficult, most people don’t bother. The rail always points the finger at the packaging and swears they never hump cars. Next time I have this problem, I’m calling Southern Bracing Systems (SBS) for a solution. SBS manufactures a patented Ty-Gard 2000® approved by the Association of American Railroads (AAR) to keep orders in tack. They also provide expert training for AAR-approved cargo securement equipment and cargo restraint systems uniquely designed to prevent damage in transit.

Problem 7: Missing Labels

In wet or grimy conditions, labels just won’t la

I’ve had to label entire warehouses: entry doors, ramps, racks, etc… Sometimes a label just doesn’t work. The Patmark 1533 provides a solution for quick, custom permanent applications. MarkinBOX is the world’s most compact portable marking machine system. Combined with a carbide pin, you can mark on a vast range of surfaces like racks and bins. I wish I had the Patmark 1533 when I 5S’d a battery storage room.

Problem 8: Data Overload

We’ve all heard the phrase “big data” but what do we do with it?

Big data creates value when leaders can make data-driven decisions. With all the data coming from the WMS, ERP, and time clocks, who has time to consolidate the data for reporting? Easy Metrics solves the big data problem by providing custom reports and KPIs for your team. I know tracking labor can be burdensome, at times requiring a full administrator. Easy metrics make it easy for everyone.

Problem 9: Packaging Dimensions

Length, Width, Height…. And where is my tape measuring?

We’ve all had to answer those questions when preparing parcel for delivery. It’s so frustrating when you have a large or heavy box that you need assistance with to get all the dimensions. Sizensor designed an app to instantly capture parcel dimensions. Sizensor has a lot of benefits around the warehouse-like planning a load diagram for new products. Consider how easy the app is to install and use, it’s a win.

Problem 10: Warehouse Space

We need more space.

No warehouse manager wants to tell their president or sales team those words. I’ve lead tens of projects to increase density and utilization. We go vertical, we consolidate, move things around, but sometimes just need more space. When you literally need to pop up a warehouse, ClearSpan is your solution. ClearSpan warehouses can be custom designs or turnkey solutions for the appropriate storage solution.

There you have it, ten solutions for common problems within a warehouse. I hope this information is useful and please share with your colleagues. Collaboration and networking is another benefit of attending conferences. All the companies listed above have great salespeople Warehouse Engineers interacted with. If these are great ideas, and you don’t have the capacity to manage the project contact Warehouse Engineers.
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Brandon Ashby, the managing partner, is a certified Project Management Professional who can manage the project for you.
modex

MODEX Day Three: Robotics & Automation Continue Maturing

In typical Modex fashion, robotics and automation were among the hot topics discussed by keynote speakers, exhibitors, and attendees. A vast array of capabilities, sizes, and industry-specific robotics could be found throughout the show floor, each showing off a new capability. It’s clear that robotics continue to evolve and show no signs of slowing down progress in meeting demand within warehouses and distribution centers.

Mike Futch, President of Tompkins Robotics made this point very clear during his session on Wednesday afternoon titled, “The Lights Out DC/FC: How Close Can We Get?”

Futch addressed the use of various technologies to address workforce constraints while improving the effectiveness and performance of the supply chain.  He identified what advancements will assist in solving bottlenecks such as facility constraints, space issues, and the current situation in unemployment. As these challenges persist, robotics continues to mature.

“There’s a limited workforce, a limited number of people that can drive the distance to enter the immediate geographic region, and these larger buildings are competing for that workforce that’s already at a low unemployment rate along with offering increased wages and siphoning workers off of others. This is a real challenge for some markets.”

“Labor is scarce and we have record-low unemployment, typically to expand capacity from a volume perspective and companies are turning to more shifts. If you already have a tight labor market and you’re adding shifts, where are the workers coming from? And this creates a bigger problem.”

The workforce is a key constraint and while workforce rates are lower than others in some places, Futch states that companies are competing to stay ahead of demand through increased wages while solving the best approach to a limited workforce.

Machines continue to do the same things a human can do but without interruptions with repetitive, difficult, or taxing work that inevitably fatigues the human body. That being said, the industry still requires a skilled workforce and robotics should not be purchased for their appeal. It’s becoming clear that a blend of workers and robotics is a more common theme for integrating such advancements over the idea that robotics will “overtake” worker’s jobs. In fact, robotics is providing a way to re-establish worker tasks rather than eliminating the worker.

“Robotics has matured tremendously from where they were a few years ago. About 5-10 years ago, the pick-and-place robots at the show could not do the things they are capable of doing now. Two years from now, they’ll have the capability to do twice as much as now. Robotics is maturing and meeting the three R’s: improve rate, improve reliability, and improve the range of products and items,” he explained. ”

In terms of a fully automated DC, Futch added that about 60-85 percent of manual tasks can be automated realistically rather than a “lights out” center.

“Beyond the pick-and-place robots, other robots are doing the same thing: creating a blur of separation between what a human can do and what a machine can do.”

modex

MODEX Day Two: Coronavirus Impacting More than Just Trade Operations

Day two for MODEX 2020 concluded with industry players addressing the now-notorious coronavirus and what this means for both domestic and international markets fortunate enough to continue operations without disruption. From what we learned during the session, “Coronavirus and Global Supply Chains” the wave currently felt in China, Italy, and beyond, will eventually make its way to the U.S. and companies have no reason not to be prepared.

Researcher Philip J. Palin, John Paxton with MHI, and David Shillingford with Resilience360 took the unsettling topic head-on and addressed concerns without hesitation. Traders be aware: for domestic and untouched international markets, the worst isn’t over. The coronavirus creates more than just health concerns. It impacts trade operations, legal concerns, and causes financial turmoil as we’ve already started to see.

“The virus is the primary cause of the supply chain impact but the secondary causes coming from the virus include financial, regulatory, compliance, and legal,” explained Shillingford. “Another risk to think about is workforce risk. How many of the workers that left for Chinese New Year have been able to come back, and for those that have returned, are they able to work with open factories or are they still under quarantine?”

“The good news is, the extraordinary supply and demand disruption we’re discussing in terms of China is being released. It’s slow but it’s happening and it’s giving us a benchmark of for how long domestic disruption will be,” Palin stated after announcing the first containership from China arrived at the Port of Los Angeles in almost 10 days on Monday.

Shillingford goes on to explain the shifting patterns in consumer behavior as well, noting that due to worldwide panic, demand is shifting and challenging the logistics sector. Buying habits have undoubtedly changed in recent weeks along with mindsets. Interactions are now limited to a fist-bump or elbow touch rather than a handshake and the numbers of public events cancelled are going up.

“Other things we are seeing involve personnel movement. It’s not just transportation impacted,” Shillingford added.

On the legal side of the crisis, Chinese suppliers are having an issue with certificates and contractual obligations. Shillingford urges industry players to understand the importance of knowing if suppliers have been issued force majeure slips.

“One thing supply chains hate is variance, and there’s going to be a lot of variance and volatility on the demand side,” he concluded.

What does all this mean for the U.S.? At the end of the day, it’s a matter of preparation and strategizing for the more fortunate markets without the disruption of a complete shut-down.

“There was a hidden, horrible problem in the Hubei province that required a draconian measure to prevent transmission of the virus. We should be ahead of that curve as well as the rest of the world, even with this very contagious virus,” explained Palin. “And even if we are behind that curve, we don’t have 300 million workers separated from their place of work.”