In warehouse fulfillment, regardless of whether the customer’s order contains car parts, jewelry, books, or medical instruments, order accuracy is the number one priority. Delivering an accurate order to every customer is the baseline for measuring success in fulfillment. It is the essential foundation upon which everything else is built. The second priority that follows closely behind accuracy is fulfillment speed. As operations ramp up with peak season or company growth, order accuracy becomes much more challenging because of the sheer volume of orders that need to be processed.
Any process involving human operators carries the risk of errors. This is the same with warehouse fulfillment operations. With manual fulfillment, orders could be picked incorrectly, contain an extra item, have the wrong label placed on the box, or be sorted to the wrong carrier.
Automation reduces errors by ensuring consistency and eliminating human mistakes. We rely on tracking orders and SKUs with unique barcodes. We track the progress of every order along the conveyor using induct verification scanners and perform parity checks at each stage of the fulfillment process. For engineered automation systems, we aim for over 99.5% accuracy, while attempting to operate at a high rate of speed (typically between 15 to 60 CPM).
Even with fulfillment automation, inaccuracies can still occur. Customers can still get the wrong items, or carriers can lose them in shipment. Without much recourse or proof other than scan data, warehouse leaders have a hard time proving they fulfilled the package accurately. But now, with unique vision camera systems we can.
Introducing StreamTech PackSight™ Camera Capture System:
StreamTech Engineering developed a camera vision system called PackSight™. The PackSight™ system does more than just capture images—it records high-resolution pictures of each completed order, whether open or sealed, as it moves along the conveyor. These images are then logged in a searchable database by the LPN (order ID).
Here are some ways this technology can enhance your operations:
Customer Service Insights: Provides data to customer service teams. In case of a complaint, operators can search the LPN database to verify whether an item was picked or not.
Carrier Accountability: Direct images of outgoing packages and contents help trace discrepancies to the carrier.
Internal Pick & Pack Auditing: Tracks accuracy in the pick and pack process using image capture and future machine vision capabilities.
Closed Box Imaging: Captures images at key stages like case sealer exit, label verification, and post-sort for damage claims.
Works well for both open box (pick audits) or sealed package (missing/damaged claims)
Images are saved to a mass storage system and indexed by scanned barcode data
Can perform binary package classification
Pairing The Image & Order Data: It’s More Than Just A Camera
You might ask, “Why not just use an IP camera to track my orders?” While a traditional camera can capture images of the items and shipping labels, the real challenge lies in organizing and tracking this data. For example, if you need to find an order labeled at 11:45 p.m. on January 3rd, you’d have to sift through hours of footage, which could include over 900 boxes if your operations runs at 15 cartons per minute. Searching through this footage wastes valuable time and effort. With PackSight™, that hassle disappears. Images are automatically linked to each order, allowing you to pull up the exact information you need in seconds. No more searching, no more guesswork.
The PackSight™ is a revolutionary system that offers more than just image capture. At StreamTech Engineering, we read the License Plate Numbers (LPNs) of each order, enabling precise tracking throughout the fulfillment process. As your order moves through each stage, the LPN is scanned and instantly communicated back to your Warehouse Management System (WMS). PackSight™ scans and logs each order by its unique LPN, giving you real-time images of open and closed cartons, as well as the shipping label details.
At StreamTech, we’re committed to enhancing efficiency and order accuracy in e-commerce fulfillment. We specialize in crafting tailored solutions that address core operational challenges, seamlessly integrating into your workflow. Through expert guidance and innovative engineering, we’ve helped countless businesses streamline their processes and improve both reliability and speed within their supply chains.
Ready to revolutionize your fulfillment process? Discover how PackSight™ can streamline your operations, improve accuracy, and elevate customer satisfaction.
Over the past few years, goods-to-person (G2P) robotics have revolutionized warehouse fulfillment by significantly enhancing picking speed, accuracy, and efficiency. These advanced robots have transformed traditional workflows, reducing the need for manual labor and minimizing human error.
However, these technologies are not standalone solutions to the entire warehouse fulfillment process, and are not intended to replace traditional warehouse automation systems. Rather, in order to realize the full potential of automated warehouse operations, G2P robots must be seamlessly integrated with conventional technologies such as conveyors, end of line print and apply labeling systems, and in some cases, automated packaging equipment. This comprehensive integration ensures a streamlined, end-to-end fulfillment process that maximizes efficiency, reduces costs, and improves overall service quality.
Material Flow In An Integrated Warehouse
The material flow in a modern warehouse equipped with Goods-to-Person (G2P) robots and integrated technologies is a seamless and highly efficient process. Here’s a breakdown of each step involved, highlighting how different technologies contribute to a streamlined operation.
Picking Process
G2P robots efficiently bring items to designated picking stations where human workers or automated systems can quickly access the products needed for each order. This minimizes walking distances and waiting times, significantly speeding up the picking process.
Transportation To Packing Stations
Once items are picked, conveyors play a crucial role in transporting these items to the next stage — packing. Conveyors are configured to handle various types of goods delicately and efficiently, ensuring a continuous flow from picking to packing without manual intervention, thereby reducing bottlenecks and errors.
Packaging
At the packing stations, automated packaging equipment takes over by creating the appropriate box or bag tailored to each specific order. This machinery adjusts to the size and fragility of items, optimizing material usage and ensuring that products are securely packaged for transit.
Scanning, Weighing, And Dimensioning
After packaging, the next step involves scanning, weighing, and measuring the dimensions of each package. These details are crucial for inventory tracking and quality control. The collected data (package ID, weight, dimensions) is then sent to Transportation Management System (TMS) software, which manifests the correct shipping label based on the package’s destination, weight, and shipping requirements.
Labeling
These systems automatically print and apply shipping labels to the packages as they move along the conveyor. This automation ensures that the labeling process is not only fast but also accurate, reducing the chances of human error and ensuring that each package is ready for dispatch without delays.
Sortation
The final step in the material flow process involves sortation. This system sorts the labeled packages according to customer rules, which may include product type, shipping destination, carrier, or service level. Sophisticated parcel sortation systems can handle high volumes of packages and sort them accurately at high speeds, ensuring that packages are routed correctly to their final destinations.
Integration Examples With G2P Robots
In modern warehouse operations, Goods-to-Person (G2P) robots play a crucial role in enhancing efficiency and streamlining processes. This section explores practical examples of G2P robots integrated with other technologies within different warehouse stages. Through these real-world scenarios, we’ll see how G2P robots effectively reduce manual labor and improve operational workflows from receiving to shipping.
Example 1: eCommerce Order Fulfillment
Imagine a bustling online retail company that specializes in a wide range of consumer electronics—from the latest smartphones to high-end laptops. To manage their massive inventory and fulfill orders quickly and accurately, they turned to an advanced warehouse automation solution.
Picking: The first step in the order fulfillment process involves state-of-the-art Goods-to-Person (G2P) robots. These robots navigate through storage racking, picking up racks as necessary and bringing them to the picking stations. Each time a rack is presented to an operator, multiple pick operations take place. This eliminates the time spent walking and searching for specific products, allowing operators to focus more on accuracy and speed, and less on the physical retrieval of items.
Conveyance: Once items are picked, they can be placed in a plastic tote which represents the order, and transported on takeaway conveyor. This tote will convey to the packaging equipment, or a packout station, to be placed in the final parcel.
Packing: Once the items are picked, they are swiftly conveyed to the packing stations. Here, automated packaging equipment takes over. This machinery is meticulously designed to handle a variety of product sizes and types, from delicate electronic components to bulky home appliances. Each item is securely packaged according to its specifications, ensuring that it is well-protected during transit and arrives in perfect condition to the customer.
Weighing, Dimensioning, and Labeling: As the packed items move along the conveyor, they enter a critical stage where they are weighed, and their dimensions are recorded. Specialized scales and dimensioning tools collect all necessary data to comply with shipping standards and help optimize space in delivery vehicles. Immediately afterward, print and apply systems efficiently add shipping labels to each package. These labels contain all essential tracking information and delivery details, ensuring smooth and traceable transit.
Sorting And Shipping: In the final step, the labeled packages are conveyed to sorting areas. Here, they are organized meticulously based on various criteria such as the destination, carrier, or service level required. This sorting process is crucial for managing the logistics of shipping vast numbers of orders daily. Once sorted, the packages are moved to the shipping areas, where they are ready for dispatch to eagerly waiting customers.
Example 2: Receiving Systems For Store Replenishment
Let’s envision a sports equipment retailer that specializes in everything from soccer balls and tennis rackets to high-end bicycles and fitness gear. Given the diverse range of products and the potential for wear and damage during transit or use, handling returns efficiently is crucial for maintaining customer trust and operational efficiency. Here’s how they could leverage StreamTech’s automated warehouse technologies to manage inventory effectively:
Receiving Goods: As soon as items arrive at the warehouse, they are placed on receiving conveyors. This initial step segregates returned goods from new inventory right from the start. This separation simplifies the processing workflow, ensuring that returned items are quickly moved to dedicated inspection stations without interfering with the flow of new stock.
Labeling: Inventory items are scanned and labeled based on their designated store locations before sortation. Upon arrival, each item is scanned to capture relevant information such as SKU, quantity, and destination store. This data is used to generate labels indicating the specific store each item belongs to. The labeled items are then fed into the sortation system, which directs them to the appropriate location for distribution to their respective store. This process ensures accurate sorting and efficient handling of inventory across multiple store locations
Sorting By Store: As items arrive at the dock door, they are placed on the conveyor system, which moves them through various checkpoints where they are scanned and identified. The sortation system then directs each item to the appropriate sort location based on the retail store it belongs with. This is done through communication with the WMS (Warehouse Management System), where inventory levels are kept. This automated process ensures that inventory is quickly and accurately sorted, reducing manual handling and expediting stocking and restocking tasks, ultimately enhancing operational efficiency and inventory management.
Robotic Put Away To Picking: In the 3D render shown above, the sorted items are headed to pallet positions, to be loaded and shipped directly to store. But if these items are being sorted for fulfillment, they could be picked up by robots and distributed into the G2P system to be picked again later if necessary.
Additional Technological Integration
Sensors: Tracking And Monitoring
In a modern automated warehouse, sensors track and monitor the movement of goods, robots, conveyors, and packaging equipment in real time. This continuous monitoring helps maintain the flow of operations and ensures that all components of the warehouse system are functioning correctly.
Quality Control
These devices scrutinize each package as it moves through the system, detecting any issues—such as misalignments or damage—that require correction, thus maintaining high standards throughout the process.
Conveyor, Labeling, And Sortation
Integration With Warehouse Management Systems (WMS): This integration ensures that shipping labels are printed with the correct order information and destination details. This helps maintain order accuracy and streamlines the dispatch process.
Conveyor Integration: Labeling systems are strategically positioned along the conveyors. As packages move through, labels are applied seamlessly, which optimizes the workflow and reduces bottlenecks.
Error Handling: The integrated systems are also equipped to detect and handle errors in labeling. This capability is essential for maintaining accuracy, minimizing the need for rework, and keeping the operation running smoothly.
Automated Sorters: Once labeled, packages are handed off to automated sorters that organize them based on their destination. This sorting process is key to improving shipping efficiency and ensuring timely deliveries.
Automated Packaging Equipment
Custom Packaging: The automated packaging equipment adjusts the size and type of packaging based on the item dimensions and specific order requirements. This customization not only ensures the safety of the items during transit but also optimizes material use.
Integration With Conveyors: As items arrive via conveyors, they are immediately packaged and then moved to labeling stations. This seamless movement is crucial for maintaining a steady flow through the packaging phase.
Benefits Of Comprehensive Integration
The integration of automated systems in warehouse operations offers a range of compelling benefits that streamline processes and enhance overall performance. Here’s how these integrations can transform the landscape of logistics and fulfillment:
Increased Efficiency
Automated systems such as Goods-to-Person (G2P) robots, automated packaging, and advanced sorting mechanisms significantly streamline critical warehouse operations including picking, packing, labeling, and shipping. By reducing the need for manual intervention, these systems allow operations to flow more smoothly and rapidly, drastically cutting down on cycle times and enhancing throughput.
Enhanced Accuracy
One of the standout benefits of automation is its impact on accuracy. Automated systems minimize human errors in order fulfillment processes, from the initial picking of items to the final shipping stages. This precision is crucial in ensuring that every package is correctly and securely prepared for shipment, significantly reducing the incidence of customer complaints related to incorrect or damaged goods.
Scalability And Flexibility
Automation provides the scalability needed to adjust operations based on fluctuating demand. Automated systems can be programmed to handle different volumes of work, making it easier to ramp up operations during peak times and scale down when necessary. Additionally, these systems offer the flexibility needed to adapt to various warehouse layouts and manage a diverse range of product types, allowing companies to expand their product offerings without compromising operational efficiency.
Cost Reduction
Integrating automated systems can lead to substantial cost savings. By reducing the reliance on manual labor, companies can lower their labor costs. Furthermore, the increase in accuracy and efficiency helps minimize costly errors and reduce waste, saving additional time and resources. Over time, these savings can contribute significantly to overall profitability.
Improved Customer Satisfaction
Faster and more accurate order fulfillment directly contributes to higher customer satisfaction. When customers receive their orders quickly and without issues, their overall satisfaction increases, which is likely to lead to repeat business and positive word-of-mouth. In competitive markets, the ability to consistently meet customer expectations with reliable and efficient service can be a significant differentiator.
Unlocking The Full Potential Of G2P Robotics Through Comprehensive Integration
In conclusion, while G2P robotics have significantly advanced warehouse fulfillment, their true potential is unlocked when integrated with traditional technologies such as conveyors, print and apply labeling systems, and automated packaging equipment. This holistic approach ensures a seamless, efficient, and accurate end-to-end fulfillment process.
To achieve this level of integration, it is crucial to work with a material handling integrator who can expertly bring together all these components, including the necessary software and controls. Such an integrator ensures that the entire system operates cohesively, maximizing efficiency and minimizing disruptions, ultimately delivering superior performance and customer satisfaction.
To explore how StreamTech can help your organization achieve an integrated, intelligent warehouse, contact us today. Our team of experts is ready to provide tailored solutions that meet your specific needs and help you navigate the complexities of modern warehouse automation.
We know that dealing with order errors in the fulfillment process can feel like a never ending battle. It’s frustrating, time-consuming, and, frankly, a bit disheartening when the hard work of your team doesn’t translate into flawless operations. Every mispicked item or incorrect order not only reflects on the team’s efforts but can also ripple out, affecting customer satisfaction and your bottom line. It’s the kind of challenge that can keep you awake at night, wondering how to tighten up those processes and ensure that what goes out the door is exactly what your customers are expecting.
At StreamTech, we specialize in enhancing warehouse accuracy and efficiency with smart, practical automation technologies – such as our pick-to-light systems. Designed to reduce manual order picking errors, the system relies on our WCS Picking Software and LED light devices to direct the operators. Our technology addresses key logistics challenges, improving both operational performance and customer satisfaction.
In this post, we’ll dive deeper into how to improve warehouse picking speed and accuracy through our Pick To Light system.
What Is A Pick To Light System?
Our Pick-to-light system streamlines warehouse picking by guiding workers to item locations using illuminated displays on racks or bins. This approach combines sophisticated hardware that is integrated with our Warehouse Control System (WCS) software , to enhance fulfillment accuracy.
The system’s hardware includes light displays and sensors on storage locations. When an item needs to be picked, its corresponding light illuminates, directing the picker. After picking the item, the worker signals completion by pressing a button or triggering a sensor, telling the system to move on to the next item. This direct feedback loop ensures a smooth and efficient picking process which can increase the pick rates per person.
The other crucial component involved is the software. The WCS Picking Software is connected to the customer’s Warehouse Management System (WMS) software, and the two software platforms work in close conjunction with one another. While the WCS Pick Software manages the hardware LED devices and screens, the WMS manages the orders and the most efficient picking routes. It dynamically adjusts to changes, managing multiple orders and maintaining real-time inventory accuracy. Integration with the WMS is seamless, allowing for instant updates and analytics, which are essential for optimizing operations.
Key components like light displays, sensors, and barcode scanners are central to the system’s functionality. Barcode scanners add an extra layer of verification, ensuring the right item is picked to help keep inventory records precise.
Picking Automation Strategies:
There are a few different ways we can employ this picking system. It all depends upon how each customer’s warehouse is structured, how the orders are fulfilled, and what fits best with the flow of the operation.
Velocity Picking Mod: The light directs the picker which bin location to retrieve from the inventory rack. Typically in this configuration, a conveyor system is positioned along an inventory picking rack, which is filled with “high movers” – the most commonly picked items. An empty carton progresses along the conveyor, and when inducted by a scanner, the lights signal on the bin location, along with a quantity shown on the display.
Wireless Smart Carts: The lights direct the picker which empty carton to place the items in. The operator pushes the smart cart to the correct aisle and bin location, and uses a gloved hand scanner to scan the bin location (as a verification step). The lights on the cart correspond with empty orders that need to be filled. When the inventory bin is scanned, the light devices indicate both a quantity on the display, and a location.
Put to Light (Put Wall): This is used in reverse logistics, returns processing or inventory replenishment. It can also be used for simply sorting and storing orders until they are completely picked, to be processed in batches. In this method, workers start by scanning items, instead of empty order cartons. When an item is scanned, the system directs the worker to the appropriate location for restocking. Lights indicate the specific rack and bin location where the item should be placed.
How Does The Pick-to-Light System Reduce Errors?
Now that we understand how the Pick-to-Light system works, it’s time to explore all the ways that it can help increase accuracy and improve picking rates (or speed).
Increasing Pick Accuracy
By lighting up the exact location of the item that needs to be picked, the Pick-to-Light system helps take human errors out of the equation. Warehouse employees no longer need to second-guess if they’ve grabbed the right product or waste time squinting at product codes. When the light goes on, your team knows exactly where to go and what to pick. We have two different methods for this, depending upon the type of pick-to-light implementation:
Training and Learning Curve Traditionally, training pickers can be a time-consuming process with the complexities of warehouse operations and the daunting task of memorizing product locations. Pick-to-light systems help make the onboarding process smoother and quicker, as new team members simply need to follow the lights. This reduces training time significantly and allows new employees to become productive members of the team faster than ever.
Enhancing Inventory Management Keeping track of inventory can feel like trying to solve a complex puzzle with pieces that constantly move. A Pick-to-light system simplifies this challenge by providing real-time updates every time an item is picked. The tight connection between the WMS and the StreamTech WCS Picking Software provides a constant flow of information that keeps inventory levels accurate, reducing the chances of stock discrepancies that can lead to overstocking, stockouts or mis-picks.
Improving Order Fulfillment Speed In today’s fast-paced market, speed is of the essence. Customers expect their orders to arrive yesterday, and pick-to-light systems are how we meet those expectations. By streamlining the picking process, orders are fulfilled faster, leading to quicker turnaround times and happier customers. It’s a direct link between the efficiency and effectiveness of your operations and the satisfaction of your customers, showing that when you invest in making your processes better, everyone wins.
Example: An eCommerce business specializing in apparel and accessories turned to a pick-to-light system to tackle its growing issue of order inaccuracies. Before the implementation, the company faced a significant challenge with order fulfillmenterrors, leading to customer complaints, returns, and exchanges that not only impacted customer satisfaction but also inflated operational costs.
Our Pick-to-Light system was integrated into their existing warehouse management system, providing a seamless transition that immediately began to show results. Each picking station was equipped with light indicators and sensors, guiding warehouse staff directly to the correct products and quantities required for each order. This visual guidance system significantly reduced the likelihood of shipping errors.
Within the first quarter of implementation, the company reported a remarkable reduction in order fulfillment errors—down by over 60%. This improvement was directly attributable to the accuracy provided by the pick-to-light system.
The company also observed a notable increase in order fulfillment speed, with order processing times reduced by nearly 30%. This efficiency gain not only enhanced customer satisfaction through faster delivery times but also allowed the company to handle a higher volume of orders without additional labor costs.
Ready to Reduce Errors With Pick-to-Light?
At StreamTech, we’re all about looking for ways to improve efficiency and streamline e-commerce fulfillment, especially when it comes to our pick-to-light system. We craft solutions that solve issues at their core and are customizable to fit seamlessly into your operations. Through a blend of expert advice and innovative engineering, we’ve guided many businesses toward smoother operations, bolstering both the reliability and efficiency in their supply chain processes.
Let’s explore how we can do the same for you, making your operations faster, and more accurate – to the delight of your customers.
The fulfillment area of your warehouse is comprised of a variety of functions, from inventory receiving and replenishment, to picking, packaging, transporting, shipping, sortation, and more. All of these discrete areas of the warehouse have a wide range of requirements, inputs, and outputs, as well as nuances based on the type of products and customers involved. These nuances all have to be managed by a central software that handles the hand-off between all of these various systems and the software databases that also manage each of these systems.
A WCS Warehouse Control System is a real-time, integrated control solution that manages the flow of items through the warehouse. They act as a traffic regulator for warehousing activities, with the mission of running material handling systems (and in some instances, the activities of workers). A good WCS system provides a broad, yet consistent interface for material handling systems like conveyors, carousels, palletizers, sorters, etc. This can result in great ROI for warehouses.
Key WCS Functions:
WCS manages the operations of many types of material handling equipment
WCS exchanges real-time communication of information
WCS can synchronize the operation of automated systems, labor, and material
WCS unifies the interface and control of automated equipment
WCS focuses on one warehouse at a time
WCS sits in a layer that connects directly to automated equipment. It adjusts at the level of a single piece of equipment — and often through an entire facility. It can modify the behavior of shipping systems, conveyors, sortation, pick and pack automation systems, etc. WCS may also be integrated into wider essential systems to streamline warehouse management operations. For example, security devices like dome cameras, alarms, and access control systems may send real-time data to WCS, enabling stakeholders to receive automated alerts regarding security incidents.
If your warehouse were like a smart home – you have blinds, doorbells, cameras, garage doors, water sensors, light switches, TV’s, speakers. Would you rather have multiple apps on your phone to control every single one of these devices, or would you rather have one app where they’re all organized and controlled? This central control is the WCS for your warehouse.
See StreamTech’s WCS Software:
What Software Connections Does It Make?
A successful automation system is about more than just hardware. Yes, the WCS manages picking, packaging, shipping and sortation equipment from a variety of different manufacturers, orchestrated perfectly together to meet your daily business requirements. However, in this digital age, we cannot overlook the software and database connections that the WCS must also make, to your WMS, ERP, order management and/or multi-carrier platform.
In a fulfillment automation application, in order for the hardware to perform tasks such as assigning weight, dimension data, pick status, packslip status, sort location or other information to an order, it must be connected to your multi-carrier or order management software. The connection to these platforms allows the data to be powerful enough to do things like rate shopping in real-time from the weight and dimension data, perform address verification, proof of delivery, and other important functions for your company and ultimately your customers. Read this excellent article from MHI’s Warehouse Automation Blog on other warehouse software, and how the WCS fits together.
What WCS Capabilities Should You Expect?
When looking at fulfillment automation integration partners, choose one who has a warehouse control software that is robust, proven, and that you can trust with your physical hardware and data. A warehouse control system (WCS) directs “real-time” activities within warehouses and distribution centers. They act as a traffic regulator for warehousing activities, with the mission of running material handling systems (and in some instances, the activities of workers). A good WCS system provides a broad, yet consistent interface for material handling systems like conveyors, carousels, palletizers, sorters, etc.
Interface to HMI’s, can be shown directly within the software application
Built-in browser, interfaces to any web-connected hardware
Defined user roles – administrator vs. operator
Built-in hardware troubleshooting test functions (test labels for printheads, boundary, other testing)
Search by order, LPN, tracking number, category, status, lane etc.
If you are a warehouse worker or someone seeking warehouse job options, it’s crucial to be aware of Warehouse Control Systems (WCS), as they greatly enhance efficiency and organization within the warehouse environment.
StreamTech’s engineering and software development teams are constantly researching and incorporating new features to increase the capability of our WCS. For more information, or if you would like to discuss your fulfillment operation with us, please fill out the form below or give us a call.
Why is a package inspection system important? In fulfillment automation, the integrity of the box is critical to the success of the automation, particularly with regard to dimensioning, labeling, conveyance, and sortation. We look for ways to add value to both our existing customers as well as new ones, and our controls and software engineers regularly explore new technology to solve problems.
Poor box integrity causes a variety of problems for the rest of the fulfillment automation process, so we have invested in research and technologies that can allow us to catch problems early.
What Are The Implications Of Poor Box Integrity?
Let’s look at an application such as our Sprinter™ dimension, weigh, scan, print, and apply labeling systems (also referred to as a SLAM system). These are integrated downstream from either a case erector, taper, or some other box right-sizing system (or a person).
To proceed successfully through these processes, the box must be properly closed. Poorly taped or glued boxes create issues with print-apply and dimensioning systems – for example, label adhesion, and incorrect dimensions. Boxes were getting labeled and sorted correctly, but (if not caught by operators) the contents of the box were being spilled out somewhere during shipment, leaving customers obviously unhappy.
Some Other Implications Of Poorly Constructed Boxes Could Include:
Loss of contents during conveyance, sortation, or shipment
Wasted time chasing down inaccuracies
Incorrect label application
Damage to the order contents or the labeler’s tamp during application
Bad dimension data due to interference with major/minor flaps (incorrect box height), which would cause incorrect multi-carrier rate shopping, costing you money
In order to catch these errors before they become such a big problem, we employ specialized sensors which integrate with the Sprinter’s WCS software, to detect these problems and prevent them from costing you money. Let’s explore how it works.
How Does This Technology Work, And How Do We Use It Within The Automation?
StreamTech uses LiDAR, projecting a laser over the surface of the object, and reading it back, to identify whether it is flat, open or closed. In this implementation, if the object is flat, the system will deliver a “PASS” reading, and allow the package to continue. If it detects an uneven surface that does not meet the required parameters, it will deliver a “FAIL” result, and proceed with the necessary corrective actions.
After a package passes through the package inspection system, this data is transmitted to our PLC, which can:
Flag improperly sealed packages prior to the print-apply shipping system, and send a signal to the printer to inhibit the label from applying.
Inhibit the dimensioner to prevent inaccurate heights.
Alarm a status light and stop them in their place on the conveyor.
Sort them to the “jackpot” lane.
Additionally, this system could be a great way to gather data on your carton sealing or lidding equipment and catch maintenance problems early before they become too costly. Data can be fed back into our Warehouse Control System (WCS) software, to report on and log which orders, which equipment, and/or on which lane these errors are most frequently occurring.
This laser-based detection system is not necessary for every application but can be a very helpful tool in mitigating issues that can arise from poorly constructed or sealed boxes. Automation is a balance, and incorporating the right technology can save you time, and money and make or break the relationship you have with your customer. Adding intelligent components such as this can be most effective when the PLC hardware and WCS software communicate well with each other. Learn about our WCS software, and how it can act as the central hub for your warehouse automation.
StreamTech specializes in fulfillment automation, from picking, pack slip automation, dimension, weigh, scan, labeling sortation, and more. If you are interested in finding ways to improve your warehouse operation, fill out the contact form below and we’ll set up a meeting to discuss your needs.
The FoldSerter™ automatically identifies each package, communicates with the software system to receive the correct pack slip, prints, folds, and inserts the pack slip into the carton, while scanning each page for 100% verification. StreamTech’s WCS software allows the system to deliver to multiple lines simultaneously.
Watch it In Action:
“Our clients have really embraced the FoldSerter™ product. This document inserter is a practical solution that comes from StreamTech’s deep operational experience and our expertise in controls and software integration. The Foldserter™ will help our customers increase throughput and profitability. It gives them the flexibility to handle single or multi-page documents in an automated fashion, with 100% scan verification. I believe it has the lowest complexity and provides the best value in the industry,” said Steve Horcher, Automation Engineer and co-inventor.
Foldserter™ has been implemented in a variety of industries including electronics, aerospace, government, publishing, postal, 3PL, medical and consumer products. This is why we are proud of the patent award for the FoldSerter™.
