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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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  • 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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  • 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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