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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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  • 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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  • 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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  • Carriers Are Charging By Dimweight – Here’s Why That Matters

    Carriers Are Charging By Dimweight – Here’s Why That Matters

    What Is Dimweight?

    Dimensional (DIM) weight, also known as volumetric weight is a pricing technique for commercial freight transport. This method uses an estimated weight that is calculated from the length, width, and height of a package. The air freight industry initially created DIM weight measurement. Low-weight packages that took up a lot of space were costing carriers revenue. To solve this problem dimensional weight was created which bases weight on the volume of the container. This is known as charging by dimweight.

    The Formula Looks Like This:

    (L x W x H) / DIM

    A growing number of ground trucking companies have adopted dimweight. If you are considering fulfilling e-commerce orders through a carrier that utilizes DIM weight, it is vital to get the measurements correct. To get the biggest bang for your buck, you would be wise to spend time analyzing box sizes, and also researching which products fit into which container.

    The Cost Of Not Dimensioning:

    Chargebacks are the main driver for incorporating dimensioning solutions with the overall SLAM system (as well as weigh, scan, print/apply). As carriers/shippers have incorporated stricter rules, there are added costs for parcels that exceed certain lengths as well as weights and chargebacks for inaccuracies. Chargebacks exceed the costs associated with just doing it right the first time.

    UPS charges an additional $1 fee per package if the inaccuracies on the total of your packages in a given shipment pickup amount to over $5 average per package.  A traditional fishing pole example – it’s super lightweight but very long.  If shipped based on weight alone, there would be a carrier chargeback.  For more details on these costs, check out this post from ShipWorks, a multi-carrier software provider.

    How Can You Streamline This Process?

    Getting the data correctly is a must for optimizing costs and fulfillment, but what happens if you get it wrong? The short story is you get charged. As the e-commerce industry evolves so does the cost related to fulfilling these orders. Increased prices cut into the margins for sales which means mistakes are now a direct cost to the shipper.

    Capturing all of this data and getting it correct is time-consuming and stressful. If you are now asking yourself, “How do I solve this problem?”, You are in the right place. StreamTech has successfully designed and implemented shipping automation systems that not only weigh but dimension and get it right every time.

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