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  • Inbound Receiving Systems vs Outbound Shipping

    Inbound Receiving Systems vs Outbound Shipping

    When it comes to fulfillment automation, receiving and shipping systems might look similar on the surface—scan tunnels, conveyors, labelers, sort logic—but the operational goals behind each are fundamentally different. Receiving systems are designed to capture and verify inbound inventory. Shipping systems are built to finalize and release outbound orders. Designing automation for each requires throughput equipment, tailored logic, and software integration.

    Below, we break down the key differences and design considerations for receiving vs. shipping automation.

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    (Pictured: Receiving System Sorting to Many Store Locations)

    Receiving – First Steps: Unload, Identify & Gather Data

    Receiving Part 1: Rapidly unload, identify all incoming orders, while recording accurate data about all items received.

    The initial goal of a receiving system will be to aid your team in unloading the truck rapidly, while scanning all items, recording the data about each one for reporting purposes. This initial induction point is critical in keeping accurate account of what SKUs are in inventory, how many, and also holding the delivery truck accountable for missed shipments.

    Key challenges in the initial unloading process:

    • Multi-sided scan tunnels are often necessary due to unpredictable barcode placement on items coming in from the truck
    • Difficult-to-scan barcodes due to inconsistency – some UPC, some LPN, some inkjet while others are labels
    • Receiving systems need to be able to keep a count of all items received from the truck in order to match them against expected quantities
    • Logging scan and label data for feedback to the inventory management for delivery (truck) auditing

    Receiving – Next Steps: Label, Verify, Route

    Receiving Part 2: Label, Verify and Route Inbound Shipments.

    The second step of a receiving system is to determine what action needs to be taken on each of the inbound items. Whether you’re unloading trailers of full cartons, mixed pallets, or individually packaged goods, the goal is to scan, label, and direct products to storage, crossdock, or staging for retail store replenishment as efficiently as possible.

    For some companies, the labeling process means simply routing for a store, while others will actually weigh, dimension and manifest each product straight out to the dock in a crossdocking configuration direct to the consumer.

    Other companies may simply need to put their own internal SKU tracking label on each product, and route them by product code or category.

    Key actions for the receiving system:

    • Labeling logic for compliance vs internal routing, or crossdock manifested shipments
    • Real-time database lookup (e.g., ASN reconciliation)
    • Exception handling – diverting all unknown, unreadable or mismatched items to QA station for individual review

    Shipping – System Handoff: Scan, Label & Sort

    Identify the order, gather weights, dimensions, and manifest with the carrier. Shipping automation takes over after orders are picked and packed. Systems like the Sprinter™ ensure packages are accurately scanned, labeled, and sorted to the right carrier lane based on rate-shopping and service levels.

    Key features in shipping automation:

    • Single-sided scan tunnels with controlled label orientation
    • Carrier label generation via WMS, ERP, or multi-carrier software
    • Rate shopping and manifesting
    • Sortation by carrier, service level, or zone

    Scanner and Labeling Design

    Receiving systems need to read whatever shows up—labels on any aide, sometimes upside-down, simply due to the fact that the team unloading the truck will be moving quickly, and the varieties of product manufacturers will have barcodes in different locations on their boxes. These barcodes may be labeled, or inkjetted on. That calls for high-performance, multi-sided scanning. 

    Shipping, on the other hand, benefits from label consistency because the outbound process is controlled by one party, enabling faster, lower-complexity single-sided scans.

    Similarly, receiving label logic varies by use case. Some cartons may need store tags, compliance labels, or shipping labels (in the case of crossdock). Outbound shipments almost always need a carrier label, triggered by LPN, order ID, or WMS handshake.

    Data & System Integration

    Inbound: Receiving automation often relies on pre-loaded shipment data (e.g., ASN or inbound manifest). As each item is scanned, the system verifies its identity, applies the correct label, and triggers a routing action. Real-time reconciliation helps spot discrepancies—like missing or extra cartons—early in the process.

    Outbound: Shipping automation typically works off predefined orders. As soon as a carton enters the line, it’s linked to a known order. The system verifies the match, calculates shipping rates, requests a label, and routes the package to the correct carrier.

    Exception Handling: Different Triggers, Same Need for Visibility

    • Receiving exceptions: Missing barcodes, unknown SKUs, quantity mismatches
    • Shipping exceptions: Failed scans, mislabels, invalid carrier data, dimension discrepancies

    Both areas demand visibility and smart exception routing. StreamTech’s WCS enables real-time alerts, logging, and diagnostics across both systems.

    Comparing Core Design Requirements:

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    From Receiving to Shipping: Scalable Fulfillment Starts With the Right Fit

    While both receiving and shipping automation leverage scanning, labeling, and sortation technologies, their business logic diverges. One is built to ingest and validate unknown inventory; the other is engineered to confirm and dispatch customer-ready orders.

    Recognizing these distinctions—and designing for them—is key to building automation that scales with your operation. Whether you’re upgrading a receiving dock or adding an outbound line like the Sprinter, StreamTech helps engineer the right fit for each phase of your fulfillment process.

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  • How Image-To-Order Capture Provides Accountability For Outbound Fulfillment

    How Image-To-Order Capture Provides Accountability For Outbound Fulfillment

    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.

    Specifications:

    • Acceptable image quality, 1.6 MP
    • Single lens options, limited focus option
    • White lighting solution
    • 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.

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  • The Warehouse Metrics You’ll Need for Your Peak Season Post-mortem

    The Warehouse Metrics You’ll Need for Your Peak Season Post-mortem

    The end of the year, called O-N-D (October, November, and December) in some industries, is the busiest time for fulfillment-dependent businesses (especially eCommerce). If your company does the bulk of its business at that time of year, you’re likely breathing a sigh of relief that it’s over right now. But there’s still important work to be done before you’re too far into the new year. Now is the time to evaluate your peak season, study your warehouse metrics, and make a plan for next time.

    Ideally, you’re tracking key performance indicators (KPIs) all year long. Comparing peak season warehouse metrics to both slower times and the previous year can help you identify bottlenecks and where to streamline processes.

    When is Your Peak Season?

    For many companies, peak season is synonymous with the holidays when demand for gifts and decorations is highest. But peak season can be driven by the type of product too. Demand for plenty of items—think pool toys and swimwear—peaks at other times of the year. 

    The point is, peak season is less about a particular time of year and more about how well your system can perform under pressure. How well can you keep up when orders come in at double or triple the average rate? And more importantly for those in the C-suite, what are the costs of failing to keep up?

    No matter the month, the challenges of increased demand are the same with the possibility of:

    • Order volume that overwhelms fulfillment efforts
    • Higher labor and overtime costs
    • Insufficient staffing
    • Increased returns

    A review of various warehouse metrics can help managers see exactly where their workflow needs to improve. Doing such a post-mortem soon after the end of peak season will allow enough time to budget for, implement, and train staff on the changes that will ensure things go smoother next time.

    Warehouse Metrics to Track and What They Mean

    Warehouse managers are well aware of the hiccups and glitches that made the last peak season stressful, and perhaps what they’d like to do to prevent the same problems in the future. But recommending and justifying fixes to the powers that be—whether an investment in a new piece of equipment, a revised process, or more staff—will require more than anecdotes about what went wrong.

    Various KPIs can provide reliable data points that pinpoint exactly where to adjust or focus new resources. Here are some of the most meaningful warehouse metrics for peak season:

    Inventory Turnover

    How frequently did you need to replenish inventory? This will tell you which SKUs are selling fast and which aren’t. This is important for a few reasons. First, you can plan to order big sellers more often and slow down reorders of less popular items so you’re not stuck with excess stock. Leftovers will need to be discounted or disposed of at the season’s end. Also, you may want to rearrange storage next year so high-velocity products are closer at hand.

    Order Lead Time

    Order lead time is the total time it takes to pick and pack and order. Some companies might measure their labor cost per package instead, but this metric does not take into account the lower wages for temps or entry-level staff. Order lead time gives a clearer picture of fulfillment productivity.

    There are numerous ways to increase order fulfillment rates, including creating a more efficient layout or implementing automation. Solutions like pick-to-light systems or goods-to-person robots are just two examples that can improve picking speed and accuracy.

    Downtime/System Outages

    Any equipment downtime during peak season is a problem. How much time (and money) did your team lose waiting for things to get up and running again? If machinery or software fails, it’s time to look at repairs or replacements before peak season rolls around again. Finding a partner like StreamTech with a lifetime service policy that truly has your back is essential.

    Shipping Costs

    When sales increase, shipping costs will of course follow. But peak season can see carrier costs skyrocket. Inaccurate DIM weight measurements can results in a lot of carrier chargebacks. And overweight packages can end up costing more in extra handling surcharges. The right shipping automation systems can improve the entire process, and help you rate shop in real-time.

    Accuracy in weighing and measuring is essential, as is having the right size packaging and appropriate packing material on hand. Tracking and replenishment of these supplies can be just as important as the inventory you sell.

    Backorders/Stockouts

    Did you run out of any SKUs during peak season? Sometimes unforeseen circumstances ramp up demand. Like selling out of sleds after a surprise snowstorm or a product becoming trendy out of the blue (remember when everyone would run out to get “Oprah’s Favorite Things”?) More often, backorders and stockouts are a sign of poor forecasting or a warehouse problem.

    Inadequate inventory management or order management processes and software can make it impossible to keep up. There could also be a supply chain issue. Perhaps those responsible for supply orders didn’t take into account the vendor’s lead time. Or, maybe it’s time to look for a more reliable supplier.

    Returns

    Peak season is likely to see an increase in product returns. Tracking the number is important, but so is noting the reason why people send things back. Sure, sometimes an item doesn’t fit or the recipient simply doesn’t like it, especially when it comes to holiday gift-giving. But other reasons can signal flaws in picking, packing, or shipping—and additional metrics to explore.

    For example: Customers receiving the wrong item could mean issues in the picking process. Check metrics for picking accuracy.

    Did products arrive damaged? Assuming things aren’t arriving broken from vendors and shelved anyway, there could be a lack of quality control during picking, or careless packing. Perhaps everything looked good when it left the warehouse but the package was damaged in transit, indicating a problem with the carrier—which means that it is time to find a more reliable one.

    Getting packages to the recipient on time is never more important than around the holidays. Tracking the percentage of on-time deliveries as well as returns of things that didn’t make it on time becomes important. Failures require a deeper dive into the metrics to see if delays stemmed from internal or external sources.

    Prep Now for your Next Peak Season

    E-commerce never stops, but the end of peak season is the closest you’ll get to downtime. This is the best time to review what worked and what didn’t so you can schedule and budget for any necessary changes.

    What slowed down operations and caused the most headaches in the peak season that just wrapped up? Warehouse metrics will help identify the problem areas and help point out possible solutions. Next year, it might be necessary to:

    • Increase staff, hire temporary workers, or add a second shift
    • Examine the warehouse layout and reorganize to optimize efficiency
    • Consider your supply chain management and possibly revisit existing contracts
    • Get repairs as well as preventive maintenance done before it gets busy again
    • Shop for automation solutions now while there’s plenty of time to install, test, and train staff on new equipment
    • Partner with StreamTech for automation solutions based on designs tailor-made for your warehouse flow—instead of throwing money into random machinery and hoping for the best

    Peak seasons will always be a challenge for fulfillment-heavy companies. No one can predict exactly what customers will want or what problems might arise. But the more data you can gather with warehouse metrics, the better you’ll be able to anticipate what’s likely to happen. Armed with this knowledge you’ll be able to pivot quickly and keep on track through the busiest part of your year.

    Interested in learning how automation can help you through peak season and all year long? Fill out the form below.

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  • What if Your Warehouse is the Bottleneck?

    What if Your Warehouse is the Bottleneck?

    Your Warehouse Fulfillment Operation Can Unlock Revenue:

    There are many reasons why a business might have a slow year, but rarely does corporate management think to look at warehousing and fulfillment as the bottleneck holding the business back. Instead, often times leaders point to slow sales or reduced product moving through their store (e-comm or physical). But a warehouse bottleneck may be precisely what is happening in a vast majority of companies today, especially in eCommerce.

    The steps of warehousing storage and fulfillment are, after all, the final steps in preparing a product for a consumer. Thus, they set the “pace” for the rest of the company. A slow and inefficient fulfillment process will mean a cap on just how big a company can grow (or, how costly it will become when demand begins to outstrip capacity). Lack of the ability to bring on new products (where will they be stored, how fast will we be able to pick them?). An inability to market them – what if the next promotional marketing turns out to be a huge success? Will your warehouse keep up? In today’s social media driven online environment, what if an influencer picks up your product? Will your warehouse be ready? Or will your warehouse become a bottleneck?

    This is perhaps the greatest argument for automating warehousing and fulfillment: It removes many of the barriers that are quietly, invisibly, preventing the business from growing. The good news here is that removing those barriers does not take a giant investment. Often, warehouse managers can get a huge ROI simply by automating a few key critical steps.

    Warehouse Automation Can Seem Cost Prohibitive…Until You Crunch the Numbers

    Many warehouse managers have stated that they have big plans for incorporating warehouse and fulfillment automation, especially as companies continue to face a difficult labor market, shrinking margins, and warehouse bottlenecks. But costs (and relatedly, ROI) have been one of the biggest barriers to automating warehouse functions…which means that many businesses are, unintentionally, stifling their own growth.

    On the cost side of things, there is not only the up-front cost of machines themselves, but also costs associated with re-designing workflows, setting up new machines and new systems, and maintaining everything once up and running. For most warehouse automation projects, those costs are balanced against the incremental gains in efficiency that a bit of automation brings about (for example, less time and manpower spent picking, sorting, packing, measuring dimensions, etc.)

    But there are also costs associated with missed opportunities. In our experience, a failure to automate doesn’t just mean that warehouse functions appear a little more expensive on a spreadsheet. Manual processes can be a bottleneck that prevents scaling, flexibility, and efficiency…and thus stifles growth.

    “Scaling Manually” is an Oxymoron

    Automated processes are much easier to scale. Take labor as an example. Suppose your warehouse needs a crew of 20 people to handle picking, packing, and fulfillment of 2,000 orders a day. For a while, this may seem workable. But what happens when the business grows and now needs to handle 4,000 orders a day? This level of growth is common – so do you double the staff, double the overhead cost? It simply is not financially economical to double the staff—and even if you did, you would now need more space, more managers, more training, more complexity in the work schedule, and so on.

    On the other hand, not doubling staff means a reduction in throughput. Those 4,000 orders will take at least two days, putting you a day behind schedule every day. Pretty soon, the warehouse will be overwhelmed, and you will not be meeting your customer expectations, or if you fulfill on behalf of others, you won’t meet your SLAs.

    With automation, you can take time-consuming tasks and not only do them more quickly and efficiently but also scale them easily when necessary. For example, with an automated system that has a predetermined throughput rate (e.g.: 15 orders per minute, or 7,200 per day), now the Business Development team has the freedom to pursue new products or new accounts, with a solid understanding of just how much the fulfillment center can handle in a day.

    Flexibility is Impossible When Manual

    While scale has to do with long-term growth, flexibility has more to do with the ability of a warehouse or fulfillment center to adjust to more short-term or local conditions.

    A great example of this is seasonality. An eCommerce business that sells products that are popular as gifts will likely see a surge in orders around the holidays. That surge necessitates bringing in additional labor. As the warehouse grows, this added need gets greater. But onboarding a fresh crew at those seasonal spikes is not a sustainable growth strategy.

    Flexibility is not always seasonal, though. A warehouse might also need to adjust if it launches a new product line, forms a new partnership, or offers a new service (for example product kitting). Such adjustments take time and resources to implement, and decision-makers must consider the trade-off between those adjustments and the new venture’s profitability.

    How does a manual operation deal with these changes? The best they can do is hire and fire additional labor in waves. That’s not true flexibility.

    …which brings us back to automation. If adjusting to seasonal demand or a new product launch simply becomes a matter of entering a few additional parameters into the control software for a set of machines, the cost of pivoting is now much lower. Business leaders are freer to pursue these new ventures without worrying so much about how the warehouse is going to pivot to accommodate them.

    For flexibility: A great example of how automation adds flexibility, let’s look at picking. StreamTech’s VelocityPick™ pick-to-light systems are designed to allow companies to add SKUs to their picking process as much as necessary without increasing the complexity of the pick process for each operator. The automation scans each order and directs each picker which bin location to pull from – the operator doesn’t have to know where specific SKUs are stored. They simply need to look for a light. This gives businesses the ability to rotate SKUs seasonally, slotting different items in and out as much as desired, without adding complexity to the pick process or slowing it down at all.

    Hidden Resources, Hidden Efficiencies

    Efficiency simply means doing something more quickly and accurately with fewer resources. But some efficient processes also free up resources that can be used downstream.

    For example, take Goods to Person Picking. Instead of a human picker traveling down aisle after aisle, this automation uses mobile shelving that moves atop picking robots. These robot travel around and pick up each shelf, then bring the shelves to the picker. The obvious benefits of this type of automation are the increased picking speed and efficiency. The hidden side-effect of this is an increase in the storage density of the facility. Goods to Person robotic picking removes the need for wide aisles to accommodate carts, pickers, and pallet-jacks, as the robots move under the shelving units. Shelving units only needs enough space to slide past each other. This is just one of many examples of how automating can solve warehouse bottlenecks.

    Simply narrowing aisles has been shown to free up around 20% of warehouse floor space, and some estimates suggest possible savings of 50%. So imagine the space that could be saved with virtually no aisles! What would you do with 50% more warehouse space? This is space that can be used for new activities (kitting, for example), or to add new product lines (or for 3PLs, new customers).

    Thus, automation can often reveal additional “hidden” resources and efficiencies, such as increased storage density of the facility…all without the need to expand the warehouse or acquire another.

    The Good News: Automation Can Resolve Warehouse Bottlenecks and Demonstrate ROI Quickly

    There is one additional reason why automation is linked with costs: It is the mistaken idea that automation means adding large, complicated systems to the warehouse. While it can mean this in some cases, automation can be simple, too.

    Sure, many warehouses are automating by adding small armies of picking robots and moveable shelves, all operated by a central software system. But that is a fairly advanced level of automation. Many smaller-scale automation projects realize a positive ROI much faster and can solve warehouse bottleneck issues.

    Take the simple steps of measuring the dimensions and weight of a packed box and then printing and applying the appropriate label for carrier pick-up. These are all functions that can be done easily and automatically with StreamTech’s end of line Sprinter™, which can process about 15 cartons per minute. At that rate, the system can finish about 7,200 cartons in a typical 8-hour shift (with no breaks, naturally!)

    While not as exciting as a small fleet of robots, the Sprinter™ fits the bill for automation: It can scale easily as the fulfillment center grows, it can work flexibly, and it frees up not only labor but also space that would otherwise be needed for people to sort, measure, and label packages. And this is just one example of a “small scale” automation that can realize an ROI much more quickly—typically in the first year or two.

    There is some good news. A recent report stated that in the U.S. over $9B is being invested to construct new warehouse space. This type of reporting tells us that at least some companies recognize the importance of investing in this area of their business.

    Re-imagine what your warehouse can do! StreamTech Engineering believes that efficient warehouse fulfillment is a pivotal part of any successful business. We are passionate about designing and implementing practical, cost-effective fulfillment automation systems that deliver a return on investment for our customers. Our goal is to change the way companies perceive their warehouse, making it a key to their ongoing success and growth.

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  • 3 Unexpected Ways Automating DIM Weight Controls Costs

    3 Unexpected Ways Automating DIM Weight Controls Costs

    While there are a lot of elements to running a distribution warehouse—labor, accuracy, speed, costs—at the end of the day, it is a business controlled almost entirely by dimensions. The dimensions of the space in your warehouse, of the items in your racks, down to the dimensions of each box, and even the dimensions of the truck that takes each order away…all of these need to be measured accurately in order to plan effectively.

    In other words, controlling these elements is critical to running a successful distribution and fulfillment center, and if not kept in check, you’ll find these dimensions controlling you. What do we mean by this?

    Take something simple, like packing and shipping. At first glance, it might appear that little can be done about costs here: Customers today expect free shipping, and yet carrier costs are significant, even when everything runs smoothly. Problems like inaccurate measurements of dimension and weight, or using the wrong packaging, can incur stiff penalties…making shipping even more expensive.

    While you might not have much control over the dimensions or weight of your products, getting accurate measurements of your packages for shipping—that is, getting a handle on the dim weight—can be a surprisingly effective way of controlling hidden shipping costs and chargebacks. This is made possible through the use of automated DIM weight equipment.

    Understanding Carrier Costs and DIM Weight

    To understand where some avoidable shipping costs are hiding, it helps to review how DIM weight works.

    Dimensional weight (DIM weight) is a method of pricing based on measuring a package’s volume in relation to its actual weight. Carriers adopted DIM weight as the standard for shipping charges to optimize the space in their vehicles.

    DIM weight is calculated with a simple mathematical formula:

    (length X width X depth) / DIM divisor

    The DIM divisor, also called the DIM factor, is a value set by carriers and represents cubic inches per pound. For example, the current DIM divisor for UPS and FedEx is 139, while the DIM divisor for USPS domestic priority mail is 194.

    Thus, DIM weight is determined by getting the volume of the package (based on its dimensions) and then dividing by the DIM divisor, which is then rounded to the nearest whole number. Charges are based on the resulting DIM weight or the actual weight, whichever is greater.

    Example: A box measuring 10” X 12” X 8” has a DIM weight of 7 pounds. (10 X 12 X 8)/139 = 6.9, rounded to 7. Pricing is based on 7 pounds, even if the actual weight is less. However, if the actual weight is 8 pounds or more, pricing is calculated by that number.

    Carriers use DIM Weight because it affects how much cargo they can plan to carry in their trucks (planes, etc.). Reporting the dimensions of a package to the carrier is a key to their efficiency, and so they set up incentives to do this accurately. (This is also an argument for why you need a multi-carrier TMS that can connect your fulfillment systems.)

    All that said, there can be more to your overall shipping bill than simply DIM weight charges. This is especially true for warehouses that work at scale: A few dollars per shipment might not make a difference when sending a dozen packages in a day, but when sending hundreds or thousands, small fees and pricing inefficiencies add up quickly.

    1. Avoid Chargebacks

    If a company records the wrong dimensions or weight on an outgoing package, or only lists dimension or weight but not both, two things can happen: The carrier will adjust the base charge accordingly using DIM weight, and they may also charge an additional fee (chargeback) per parcel that has missing or incorrect information. (Note that the process of correcting this can potentially delay the shipment, too.) Relying on your vendors’ inventory master lists for dimensions and weight can be problematic here—if their data is wrong, you could be paying for their mistakes! (Again, not having control of your dimensions means you will find these dimensions controlling you.)

    Fee amounts vary by shipper and fluctuate over time, but range from about $1 per package to 5% or 6% of the amount of the price adjustment. Regardless of how they are calculated, chargebacks can accumulate fast as throughput increases.

    We integrate dimensioning cameras and light curtain dimensioning systems into our shipping systems regularly.

    For all but the smallest companies, trying to accurately measure and weigh packages by hand is a non-starter. The most basic advantages of adding DIM weight machines are that they provide thorough data and eliminate human error. They can also go much faster than any manual system. Equipment like StreamTech’s Sprinter™ can scan, weigh, measure dimensions, and print and apply labels for between 600 and 1,000 boxes per hour, without making a mistake.

    2. Right-Size Packaging

    Another source of unexpected shipping fees is a handling surcharge for packages that exceed size or weight limits, or that are not in a squared box. For example, boxes heavier than 50 pounds, or measuring more than 48 inches on the longest side, can trigger surcharges of hundreds of dollars from FedEx.

    While the size of parcels can’t always be controlled, making sure to use the smallest box possible will help. We’ve all laughed when a huge box arrives at our doorstep, with one small item inside, accompanied by lots of void fill. This is obviously not efficient.

    In many fulfillment operations, the selection of the right box size (called cartonization) is left up to an operator’s sole discretion during the packout process. A material handling systems integrator such as StreamTech, can use a cartonization algorithm integrated right into our Warehouse Control System software (WCS) and take this guesswork out of the process.

    Ideally, various types of packaging equipment should be integrated which can build a box on-demand to match the size of each order. Some systems employ complex machines to build a box around each item; others build a cardboard tray, then add a lid, and still others employ robotic arms to select each box. StreamTech Engineering can work with you to help find the right equipment for your operation, all designed to control the dimensions of each box.

    Automating these processes also gives managers the tools to make better, more cost-effective packaging and shipping decisions. Perhaps orders might be split into two or more cartons so they’re not overweight, disassembled to fit in a smaller box, or more suited to an alternative packing material like a padded envelope.

    Optimizing cartonization eliminates wasted space in each parcel and minimizes the DIM weight—and therefore shipping charges. You’ll know ahead of time that something is heavy enough or big enough for surcharges to kick in, instead of being surprised with an invoice.

    3. Rate Shopping By Carrier

    Another way that automating DIM weight helps the bottom line is by allowing carrier rate shopping in real time.

    Carriers differ in their pricing models and requirements, and fees change frequently. StreamTech’s WCS software has the ability to integrate with multi-carrier TMS software. Together with accurate, automated DIM weight data, the warehouse system can automatically scan the various shipping options available, choosing the carrier that offers the best price (along with other criteria, like on-time records and return stats). Once chosen, the system can create and affix the appropriate label, further streamlining the process.


    Over time, this kind of rate shopping will allow your fulfillment center to find ways to use your annual carrier spend more efficiently, and without massive manual intervention.

    Take Control of DIM Weight Before It Takes Control of You

    Fulfillment centers live and die by dimensions; taking control of their measurement and use means controlling a large part of your costs.
    Here we’ve seen how automating DIM weight calculation minimizes the human error in weight and dimension estimation, allowing companies to avoid unexpected surcharges and maintain more predictable shipping costs. Additionally, the real-time rate shopping and automated labeling eliminate time-consuming steps, freeing warehouse staff to focus on higher-value tasks. StreamTech’s WCS software ensures that each shipment meets carrier specifications for both price and performance, enabling consistent, cost-effective delivery and enhancing customer satisfaction.

    And while measuring DIM weight may not seem like a top priority when deciding how to automate your warehouse, implementing dimensioning equipment can have a relatively large impact. When every package can be scanned, weighed, and measured efficiently, ensuring that only accurate information is provided to the carrier, things like chargebacks, special handling fees, and bad packaging decisions become a thing of the past.

    Fill out the form below or call us to discuss how StreamTech can help.

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  • Goods To Person (G2P) Robots Are Just One Piece Of An Integrated, Intelligent Warehouse

    Goods To Person (G2P) Robots Are Just One Piece Of An Integrated, Intelligent Warehouse

    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.

    Related Links

    1. 3PL Fulfillment Automation: Transforming Processes for Operational Efficiency
    2. 3PL Fulfillment Automation

    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.

    Gods-to-Person Geek+ PopPick System. Goods To Person (G2P) Robots.

    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.

    1. 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.
    2. 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.
    3. 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.
    4. 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.
    5. 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.
    eCommerce Order Fulfillment

    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:

    1. 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.
    2. 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
    3. 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.
    4. 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.

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  • How Pick to Light Systems Increase Accuracy and Speed in Warehouse Operations

    How Pick to Light Systems Increase Accuracy and Speed in Warehouse Operations

    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.

    Learn more about our WCS software ›

    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 fulfillment errors, 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.

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  • What Is Warehouse Control Software (WCS), And Why Is It Critical To Get Right?

    What Is Warehouse Control Software (WCS), And Why Is It Critical To Get Right?

    What Is WCS (Warehouse Control System) Software?

    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.

    Connections to the warehouse control software (WCS)

    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.

    Some of StreamTech’s WCS features include:

    • Realtime status of all shipped orders, including tracking ID, weight, dimension, etc.
    • Sends data to and from the multi-carrier or order database (rate shopping, address verification, proof of delivery)
    • Equipment status and error alerts (ie: printer, print head life, sensors, scales, scanners, etc)
    • Configuration and management of sort lanes and locations
    • Manages pack slip automation systems
    • Manages picking systems
    • Allows user management of multiple printer/applicators, and bypass if necessary
    • Production reports – machine availability/uptime, boxes per hour, per week
    • Data logging and exporting
    • Response time reports
    • Carton per minute reports
    • 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.

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  • Package Inspection System

    Package Inspection System

    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.

    Package inspection system with StreamTech box on conveyor belt.

    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.

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  • Why Choose Fulfillment Automation?

    Why Choose Fulfillment Automation?

    Fulfillment Automation Benefits

    So why choose fulfillment automation? There are a lot of reasons for fulfillment automation, and it ultimately comes down to increasing operational efficiency. It’s not always just about speed. As you are considering the ROI (Return On Investment) for your next warehouse improvement project, here are a few of the reasons to consider fulfillment automation. We’ll explore Labor Efficiency, Labor Costs, Speed, Customer Experience, Flexibility, and Future Growth.

    But before we explore the reasons for automation, let’s take a look at the competitive eCommerce landscape and how it’s changing.

    Booming eCommerce Growth: Automate Or Miss Opportunities

    Fulfillment automation is no longer just for the big players. In order to understand the growing demand for fulfillment automation equipment, let’s first take a look at consumers’ penchant for eCommerce shopping, because they have a correlation.

    Over the past few years, as consumers have become less interested in brick-and-mortar retail business, eCommerce has grown. From 2010 to 2020, eCommerce’s share of total retail sales grew an average of 11% YOY, steadily. Over these years, the largest share of eCommerce growth was with Amazon.

    The pandemic changed that and accelerated eCommerce growth. As consumers were pushed toward a digital life, with fewer in-person events, gas money, and stimulus money to spend, online shopping soared. From Q1 2020 to Q2, however, it grew 37%! During this time, Amazon lost market share, down from 43.8% of all eCommerce sales to just 31.4%. The other top 100 online retailers besides Amazon had a 74.1% share of eCommerce growth, up from 49.4% in 2019.

    The above numbers point to a trend – consumers have increased spending, and are spreading their shopping around a wider variety of retailers. If the effect is measurable on the top 100 retailers, it tells us fulfillment automation is not just for the big guys.

    Labor Efficiency:

    For most fulfillment operations, it is inefficient for employees to perform lots of small repetitive manual tasks, such as scanning, label application, box closure, or sorting. By introducing automation to perform these types of tasks, one employee can now oversee the system, covering multiple tasks with one person, and freeing up the remaining staff to be productive in other areas.

    Taking away the burden of repetitive manual tasks and transferring them to more supervisory roles eliminates dangerous situations. Making the operation more ergonomic and less burdensome means employees are less fatigued and less prone to injury.

    The cost of manual labor is not fixed – it is subject to increases to match the cost of living. As inflation continues, and societal and governmental pressures push for wage increases, companies are wise to look at automation to minimize this risk. Additionally, manual labor comes with other costs such as liability insurance, personal protective equipment, and health benefits. Optimizing labor also has advantages when it comes to labor shortages. The labor force has seen a reduction in the number of general laborers, which makes automation the next logical step.

    Costs:

    Aside from the cost of labor, there are other costs associated with fulfilling orders that automation can help reduce. For example, fulfillment automation introduces opportunities to reduce shipping costs. Adding the ability to measure dimensional weight allows for more accurate shipping charges, as most carriers are no longer just charging based on the weight of the carton, but also on its dimensions of it. Another shipping cost reduction comes with the ability to rate shop carriers and ship by the most efficient means possible.

    Shipping automation can handle this process very quickly and effectively, without adding much time to the process.

    Speed & Customer Experience:

    Automation makes the fulfillment process faster. Getting more orders out the door in a shorter amount of time is often the first benefit people think of when considering automation. Increasing production allows for your business to grow, take on more orders, turn around those orders to customers faster, and more accurately, and in turn, increase sales and profits.

    The other benefit of speed and accuracy is that your customers receive their orders in a timely fashion, without missing delivery expectations. With a significant increase in the number of choices in order fulfillment, excellent customer service, and personalized order experiences become a much bigger differentiator.

    Watch Fulfillment Automation in Action:

    Flexibility & Future Growth:

    One of the most unsung heroes of fulfillment automation is flexibility and future-proofing. Fulfillment automation gives you the ability to scale with your business needs. When operations are not automated, peak periods like holidays can cause a huge strain on your business – requiring seasonal labor, shipping delays, and other constraints with meeting demand.

    Automation can also allow your business to be prepared for growth. Automation gives you the flexibility to add new products and enter new markets without concern about your fulfillment operation being overwhelmed by the capacity.

    Explore Fulfillment Automation Technologies:

    When considering a fulfillment automation system, it is most efficient when it can be centrally controlled and integrated, all the way from picking, packing, shipping, and final sortation. StreamTech offers the integration necessary to bring all the automation together and maximize your return on investment.

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  • Fulfill Daily Order Volume With Automation

    Fulfill Daily Order Volume With Automation

    The Problem:

    An eyeglass fulfillment operation faced significant challenges in delivering its daily orders to over 500+ stores across the United States and Canada within designated timeframes. Despite employing several full-time workers dedicated to order fulfillment, the operation encountered difficulties in keeping up with the workload, leading to a high frequency of manual errors.

    The issue was further compounded by a typical backlog that extended a staggering 80 feet back into the packing area, severely impacting the company’s operational efficiency.

    Our Solution:

    StreamTech provided a complete bolt-on addition to the customer’s UPS Worldship application. Instead of a unique order ID or license plate, each carton had a label that simply represented a store. We also included customized end-of-day reporting. Overall the system helped the customer gain the following benefits:

    • Removing non-value added manifesting labor
    • Eliminating manual weighing and dimensioning errors
    • Clearing up backlog
    • Reclaiming floor space from many manual workstations
    • Allowing the customer supervisors to leave on-time and get home to their families.

    The local conveyor integrator noted how easily the Sprinter™ was able to control adjacent conveyors for seamless automation. Another system is on order for a second facility!

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