Part two of a two-part series. Click here to read part one: Picking Is The Star, But It’s Time To Put Inbound Process into the Spotlight
Now that you understand the critical role the inbound process plays in overall distribution center efficiency, it’s time to explore how technology can upgrade these previously overlooked areas.
When many DCs were originally designed, the cost of automated technology was high, according to Luke Nuber, Director of Sales Operations for DLN Integrated Systems, Inc. Even if the design was solid, the automated technology also may not have existed yet.
However, if you fast forward to the present, you likely will be surprised at how advanced the technology is AND how much the cost has gone down. Vision systems, machine learning, and sensor technology have all improved significantly.
“It’s worth another look,” Nuber said. “There are things you can do with robotics today that weren’t possible five or ten years ago.”
The changing labor market has also made investing in new technology much more justifiable.
“The scales are tilting: Technology is cheaper. Labor is more expensive and harder to find.”
Examples of Technology Application During the Inbound Process
RECEIVING
Receiving is the initial step involving the physical acceptance of goods, is ripe for technology additions. These can include:
- Trailer unloading equipment to improve efficiency and ergonomics
- List assistance like vacuum grippers or pallet lift tables
- Inbound sortation to automated processes, segregate products and streamline putaway
- Automated palletizers/depalletizers to speed-up inbound and avoid repetitive lifting
PUTAWAY/REPLENISHMENT
Putaway and replenishment is the process of moving items from the receiving area to the storage area. Technology upgrades can include:
- Pallet transport using Automated Guided Vehicles (AGVs) or Autonomous Mobile Robots (AMRs)
- Replenishment of carton flow with AMRs
- Handles multiple cases per tote and is configurable
- Pallet shuttles for automated storage and retrieval
- Load scanning technologies to ensure proper performance in automated solutions such as a pallet board check, pallet sizing arrays, and AS/RS location scanning systems
DECANTING
Decanting is the process of unloading goods from their original shipping containers and repackaging them for replenishment. A major technology upgrade available for that step is the PRODecant, an automated decanting robotic cell that safely opens cases and empties product into totes.
The customizable technology:
- Reduces reliance on labor by moving scarce workers from the task of opening boxes to other areas of your facility
- Automatically adapts to mixed case sizes, including depth of cut
- Handles multiple cases per tote and is configurable
- Keeps the product safe
- Operates with speed
Technology Isn’t the Only Solution
The default assumption in the industry is that the inbound process is easy and repetitive because it mostly deals with pallets and cases. Therefore, warehouse leaders assume they can automate whatever they want.
However, many things can go wrong with automation, even in these early stages.
Receiving is getting products from lots of vendors and they don’t always comply with the desired specifications. The labeling could be in the wrong spot. Or they changed the size of a carton without notifying you. This creates headaches for many automation systems that are rigid in their settings.
The robots and automation don’t know how to problem-solve.
This is where having a strong design process and an expert partner can make all the difference. You can work together to determine candidates for automation because some things are too complicated to be automated, Nuber said.
Having a good process design and training employees with instructions, can help you leverage the automation or find flexible automation.
Additional Considerations
Don’t Overlook Cycle Time
- For operations that hold low inventory levels, monitor the “dock-to-stock” time to keep stock available for order fulfilment.
- QA requirements and specific VAS (value-added service) processes are also included in inbound operations and consume time that must be considered.
- Having a proper staging space is important to enable smoother inbound product flows, and serve as buffer to help with faster release of dock doors and trucks.
Unit of Measure Transformation Involves Different Processes Such As:
- Down-stacking (or up-stacking) of pallet to fit rack location heights.
- Decanting the content of vendor cartons into totes for replenishment of an each-picking system.
- Kitting or light assembly.
Bridge the Gap Between Pallet Quality and Need for Standardization
- Recognize the level of inconsistency in pallet quality that will be received.
- Understand what processes are required to balance those inconsistencies with the need for standardization with your automated applications.
Drive Success with a Trusted Partner
Applying technology to your inbound process is important for your warehouse to operate efficiently. Often you need unbiased expertise to help you determine your individual needs.
DLN Integrated Systems is a trusted partner that is not committed to using specific brands of equipment or technology. It analyzes each situation uniquely and provides comprehensive integrated solutions using equipment and technologies from a range of manufacturers.
This enables DLN to implement the most efficient and cost-effective solutions customized for each client. Contact us to learn more!
