Barcode, RF, Pick To Light, RFID

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Pick-to-Light

Pick-to-light technology speeds up fulfillment by electronically "reading" order pick tickets, determining the most efficient processing sequence, then transmitting signals to special light bars mounted on the storage racks that house the products to be picked. The light bars then flash (so that the picker knows exactly where to go) and display the quantity to be picked. After picking the items, the warehouse worker presses a button or scans the shipping label at the light module, depending on the system, so that the computer can verify that the order was picked correctly. The picker can also report any merchandise shortages by pressing buttons on the light modules. By minimizing the time spent searching for the correct SKUs, pick-to-light technology can boost picking rates. Indeed, New York-based cosmetics marketer Avon increased the pieces picked per hour 10%-15% after installing pick-to-light technology in its four distribution centers in 1991, says Roosevelt Tolliver, vice president of customer service. The company also reduced its pick errors 50% after installing pick-to-light.

Because each light bar costs $200-$300, pick-to-light technology is often reserved for high-volume, fast-pick areas, rather than for every SKU. And most operations professionals agree that pick-to-light is best suited for catalogers that have a varied assortment of SKUs that they sell regularly, rather than just a few big sellers.

for detailed information on Pick to Light click here

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Put-to-Light

The Put to Light process is pick to light in reverse. In Pick to Light, each SKU has its own location. This means that when the order is moved into the pickers zone, each location needed for that order will illuminate, the picker will then pick the items in that zone from those locations, extinguish the lights, and pass the order to the next zone. In contrast, items for the orders in Put to Light are usually batch picked in the warehouse and brought the Put to Light system. The picker will scan an item and all the locations that need that item will illuminate. The picker will put the item to each location and extinguish the light. As soon as the order has filled, the location will illuminate and display the word "done". This order is now fulfilled and can be removed from the location and is ready for shipment.

Why Use Put to Light

Put to Light systems are SKU independent. If a company has a lot of SKU's, a location is not necessary for each SKU.
Put to Light applications are usually at a lower cost than Pick to Light because not as many locations are needed.
Put to Light is frequently used in retail type applications because the number of orders are usually consistent on a day to day basis.

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Barcode Technology

A barcode is simply a series of stripes (usually black) on a light background (usually white) that can be scanned and read directly into a computer. They are interpreted virtually instantaneously and unerringly by a barcode reading system. The elements (bars & spaces) in a barcode symbol must be of a consistent, proportional thickness & thinness. The widest element could be as thick as a pencil or as thin as a business card, as long as the corresponding thin bars and spaces in the bar code remain proportionally thin.

Bar codes are a fast, easy and accurate data entry method used in the process known as automatic data collection. Bar coding enables products to be tracked efficiently and accurately at speeds not possible using manual data entry systems. The primary benefit of this process is that it is truly automatic, occurring instantaneously as a transaction or process takes place, commonly referred to as real-time data capture and exchange within the industry. Improved accuracy is yet another benefit. Studies show that the entry and read error rates when using automatic data collection and bar code technology is approximately 1 error in 1 million characters versus 1 error for every 300 characters in manual key entry.
More info at http://www.systemid.com/education/

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RF Technology

Radio frequency technology (RF) allows mobile devices, as well as computers and printers, to communicate with each other wirelessly within a Local Area Network (LAN). This technology is extremely useful in large warehouses where having up-to-the-second information is essential to run a business in the most efficient way possible.

POTENTIAL APPLICATION AREAS

RF communication is a potential application anywhere in your operation where there is a need to get information to people or where you use paper controls. Following are some possible application areas with an indication of how the technology could be used:

Receiving

RF terminals can be used on the receiving dock as electronic receiving worksheets. RF permits real time receiving updates.

Putaway

RF terminals can be mounted on lift trucks to instruct operators where to locate products that have just been received or manufactured, and to confirm the transaction. RF permits real time updates of stock availability in the picking locations.

The possible benefits of using Radio Frequency (RF) communications are speedier transactions, paperless operations, improved control and reduced cots in your operation.

Replenishment

RF terminals can be mounted on lift trucks or other material handling equipment to direct the replenisher to a location and to confirm a transaction. Tied into a real time inventory control system, RF can virtually eliminate replenishment timing problems.

Picking

Wireless and paperless picking can be achieved through RF terminals. These terminals can be mounted on powered mobile equipment or can be hand held compact units on carts. RF permits a completely interactive system, which can be used to make a random pick location system work.

Shipping

RF terminals can be used to confirm loading operations and generate manifests. RF terminal mounted in shipping are usually similar to those described in receiving.

Yard Tractor Dispatch

RF terminals mounted inside the yard tractor can provide an interactive communication system for trailer moves.

BENEFITS

The benefits of Radio Frequency (RF) communication fall into the following categories:

• Speed-Transactions are immediate, both to and from the computer.

• Paperless operations - The printing, distribution and handling of paper is eliminated.

• Control-Transactions by person can be tracked on a real time basis to monitor a complex operation.

COSTS

The costs of a radio frequency communications system can be grouped in the following ways:

1. Terminals
2. Base Station
3. Software

SUMMARY

RF is not technology to be feared for reasons of complexity or cost. In some cases, however, it is important when considering the feasibility of introducing RF, to determine the expense involved in integrating the concept into your existing software.

RADIO FREQUENCY MATERIAL HANDLING APPLICATION

OPERATING ENVIRONMENT

This application is for a frozen food manufacturer and distributor. Operations are scheduled for six days per week and two ten hour shifts per day.

OPERATING METHOD

After the finished product has been palletized and shrink wrapped, the lift operator applies a bar coded label. The label contains a unique six digit identification number. The operator scans the bar code label and enters into his on-board terminal the SKU number, pallet quantity and the warehouse location. The computer automatically logs the time and date when the information has been entered into the terminal.

To retrieve pallets, messages directing the lift operators to specific locations are displayed on the terminal screen. Retrieval logic includes first in, first out and easiest access. Transaction confirmations of retrievals are also keyed in.

RESULTS

The warehouse now operates with a real time, paperless environment. Inventory accuracy approaches 100%. Lift truck operator productivity has been increased dramatically. A side benefit is that whenever batch quality is questioned, all pallet positions produced during a specific time period can be identified and restricted from access.

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RFID (Radio Frequency Identification Devices)

What is RFID?

Radio frequency identification, or RFID, is a generic term for technologies that use radio waves to automatically identify individual items. RFID does not require line-of-sight. Radio frequencies are used to communicate between the tag and reader. This means that an item can contain its label on the inside. There are several methods of identifying objects using RFID, but the most commoat is attached to an antenna (the chip and the antenna together are called an RFID transponder or an RFID tag). The antenna enables the chip to transmit the identification information to a reader. The reader converts the radio waven is to store a serial number that identifies a product, and perhaps other information, on a microchip ths returned from the RFID tag into a form that can then be passed on to computers that can make use of it.

How does RFID technology work?

Radio frequency identification technology is an automatic way to collect product, place, time or transaction data quickly and easily without human intervention or error.
An RFID system comprises a reader (or interrogator), its associated antenna and the transponders (Tags/ RFID Cards) that carry the data. The reader transmits a low-power radio signal, through its antenna, that the tag receives via its own antenna to power an integrated circuit (chip). Using the energy it gets from the signal when it enters the radio field, the tag will briefly converse with the reader for verification and the exchange of data. Once the reader receives that data it can be sent to a controlling computer for processing and management.

Advantages of RFID

Unlike bar code-based tracking systems, an RFID system can read the information on a tag without requiring line of sight and without the need for a particular orientation. That means RFID systems can be largely automated, reducing the need for manual scanning. In addition, RFID tags hold much more data than UPC labels. The tag can be programmed to hold information such as an item’s serial number, color, size, manufacture date and current price, as well as a list of all distribution points the item touched before arriving at a store. Some RFID systems allow companies to write information to the tag and store it there; the RFID tag then essentially acts as a portable, dynamic database. Other systems allow the information contained on the tag to be edited, added to or locked, capabilities that are particularly valuable when dealing with high-end inventory tracking and other applications when complete, up to date information (such as current pricing) is of particular benefit.

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