Zebra

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Receiving

PROBLEM: Lack of asset visibility causes congestion and errors, and negatively impacts downstream processes
When incoming inventory data isn't accessible in the Warehouse Management System (WMS):

Shortages and discrepancies cannot be easily identified
Scanning errors, incorrect labelling and lack of labelling cause bottlenecks
Productivity suffers

SOLUTION: Increase visibility during receiving with mobile computers, scanning and printing solutions that increase velocity and accuracy

Mobile access to WMS during receiving enables managers to scan and reconcile incoming inventory
Label incoming goods on the spot with mobile printers to streamline put-away
Save time by eliminating the need to move to a fixed computer terminal

RESULTS:

Boost productivity
Provide instant inventory visibility and availability
Eliminate dock congestion
Error-proof the receiving process

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Put-away & Replenishment

PROBLEM: Bottlenecks and processing errors cause higher dock-to-stock cycle times
When errors occur, downstream processes are affected:

Materials may need to be moved more than once, wasting valuable time
Inventory in multiple locations increases picking time
Purchasing cycles and manufacturing schedules are difficult to manage

SOLUTION: Ensure virtually error-free put-away with mobile printers and handheld computers
Combine with real-time locationing systems for even more rapid, accurate put-away:

Workers have the exact locations of both inventory en route and final storage
Upon put-away, status of goods is updated immediately in warehouse management system (WMS) to show in-stock
Workers can complete transactions in the put-away aisle instantaneously

RESULTS:

Improve processing time up to 62%¹
Save up to 30 minutes per worker, per day¹
Reduce dock-to-stock cycle times
Optimise inventory availability and accuracy
Enable prompt order fulfilment

1. Zebra Technologies Research: Warehouse Infographic 2015

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Inventory & Materials Management

PROBLEM: Lack of accurate fulfilment and cycle count data results in lost productivity and revenue
Misplaced or miscounted inventory can result in:

False out-of-stocks and lost sales
Costly, unnecessary repurchasing and storage

SOLUTION: Easily track important assets in real time with mobile handheld computing
Identify racks and fixed inventory locations with barcode or RFID labels to:

Improve productivity, inventory visibility and utilisation of MHE
Confirm correct item placement
Confirm inventory levels of every asset in your warehouse

RESULTS:

Get faster cycle counts with fewer workers
Ensure regulatory compliance
Improve accuracy and order fulfilment

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Picking

PROBLEM: Inaccurate location information leads to picking errors and inefficiency
Inaccurate fulfilment can result in:

Difficulty meeting same-day shipping demands
Costly returns and sanctions imposed by vendors

SOLUTION: Improve efficiency with hands-free data capture and mobile solutions
Hands-free, voice-directed and multi-modal wearable picking solutions:

Automatically deliver pick lists and optimised routes to mobile devices
Allow workers full use of their hands
Guide workers directly to items

RESULTS:

Achieve 99.9% picking accuracy, virtually eliminating returns²
Improve efficiency and accuracy to facilitate same-day shipping
Increase productivity per worker to pick more orders per day
Reduce training requirements for temporary and seasonal workers

2. 2015 Zebra Technologies Warehouse Vision Report

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Packing & Staging

PROBLEM: Inefficiencies and errors result in space utilisation issues, higher reshipping costs and customer dissatisfaction
Manual processes and visual order inspections can be inaccurate:

Busy packers may not catch slight differences in similar items
Single items on multi-line orders are easy to miss visually
Addresses can be entered incorrectly
Large orders could be misplaced or separated during dynamic staging
Inefficient use of space can’t accommodate spikes in demand

SOLUTION: Improve speed and accuracy in these last touchpoints with barcode scanning, vehicle-mounted computers, RFID and locationing (RTLS) solutions
Automated data capture, instant verification and dynamic outbound staging locations allow you to:

Confirm orders are complete and correct items were picked
Guarantee shipping details are accurate
Ensure items are instantly deducted from inventory as they are picked
Eliminate out-of-stocks
Significantly reduce staging errors including missing cartons or skids

RESULTS:

Ensure order and shipping accuracy
Eliminate reshipping costs
Increase speed and efficiency
Reduce dedicated staging areas for greater space efficiency

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Shipping

PROBLEM: Trailers are not being loaded to optimise space, increasing operational costs
Inefficient loading processes lead to:

More lorries on the road, increasing fuel and maintenance costs
Delayed deliveries due to loading errors
Damaged packages

SOLUTION: Improve loading processes with mobile computers, scanners and data-driven analytic solutions
Verify barcoded shipping information using mobile computers, scanners and BLE beacons to:

Ensure packages are being loaded on the right lorry
Utilise captured package dimensions to optimise use of trailer space
Send confirmation to warehouse management system (WMS) that packages have been loaded

RESULTS:

Increase profitability
Improve parcel visibility and traceability
Promote customer satisfaction
Ensure faster, more efficient loading processess
Provide accurate delivery information

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Cross-Docking

PROBLEM: Without real-time visibility into the order database and assets, speed and accuracy suffer
Manual procedures decrease efficiency and efficacy of warehouse operations:

Workers handling shipments multiple times leads to poor utilisation of material handling equipment (MHE) and personnel
Order status cannot be updated quickly for customers
Shipment delays and routing errors impact customer service, satisfaction and retention

SOLUTION: Pair RFID and BLE asset visibility solutions with mobile and vehicle computers for real-time order database access
With greater access and visibility, workers can:

Process incoming shipments and aggregate those assigned to the same dock
Ensure shipments are delivered to the right dock at the right time, and loaded onto the right lorry in the right order
Efficiently direct lift lorry operators to the nearest trailer

RESULTS:

Improve utilisation of MHE and personnel
Increase speed, accuracy and efficiency
Maintain up-to-the-second inventory
Increase customer satisfaction
Eliminate delays during delivery

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Reverse Logistics

PROBLEM: Lack of visibility across channels increases customer frustration and restocking time
Processing returns is more complex with multiple commerce channels:

Brick and mortar stores can’t access order history to process online purchase returns
Delays occur as workers validate returns, identify and assess items and process credits
Returned goods are often misplaced or not labelled, reducing efficiency
Stores may not have visibility into distribution centre inventory—and vice versa

SOLUTION: Improve the customer experience with mobile printing, scanning and computing
Workers can process returns and reshipments in an instant as well as:

Identify returned items—whether purchased online or in-store—with barcodes upon receipt
Take photos of returned goods to eliminate disputes over the condition
Validate the status of a return, issue credit and notify the customer instantaneously
Ensure items are added to inventory and instantly available for fulfilment of new orders

RESULTS:

Reduce overall processing time
Improve worker productivity
Reduce unnecessary reordering
Restock goods promptly
Protect customer satisfaction levels

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