In the past 30years the role of the warehouse operation has drastically changed and it has already moved away from its very basic core functions such as the receiving, storing, tracking and supplying of finished stock keeping units (SKUs) to various customers, or the supply of raw and packing materials to factories for their eventual manufacture/conversion to finished goods.  

In our today’s warehousing environment more emphasis is being placed on matters related to speedy but accurate receipt and delivery of SKUs, the optimum warehouse space utilisation, the correct use and proper application of all material handling equipment (MHE), the application of lean process and the 5S Technique all the way to ensuring their customers’ satisfaction and retention, but most importantly to safeguard their loyalty.

In our today’s warehousing environment more emphasis is being placed on matters related to speedy but accurate receipt and delivery of SKUs.

Owing to the complexity and sophistication of the today’s warehouse operation, its role provides a twofold benefit, aiming to achieve an optimum position between minimising the total cost of operation, whilst providing the expected service level for the business.   
In view of this fast changing environment, the employees involved in the warehouse business must be well equipped with all relevant knowledge as their role has substantially been upgraded to a higher level.

In the light of this, I have selected four advanced warehouse technologies (could I say my favourite ones?) and I would be more than happy to share these with you all.
These are:     

• Voice Technology
• Pick-To-Light
• Automated Storage & Retrieval Systems (AS & RS)
• Pick N Go Order Selection

• Voice Technology

A new way for warehouse workers, which enables them to communicate verbally with the system via radio frequency.  It is similar to RFID technology, but this is more advanced.

Voice technology uses speech recognition and speech synthesis to allow warehouse workers to communicate with the warehouse management system (WMS).  Warehouse workers use a wireless, wearable computer with a headset and a microphone to receive instructions by voice and to verbally confirm their actions/results back to the system. This wearable computer, or voice terminal, communicates with the warehouse management software via a radio frequency (RF) local area network (LAN).

Voice technology uses speech recognition and speech synthesis to allow warehouse workers to communicate with the warehouse management system (WMS).

Each warehouse worker/picker needs a belt-worn, wireless terminal, which consists of a headset with a microphone and receives instructions by voice and verbally confirms actions back to the system. For instance:

In a voice technology operating warehouse environment an order picking application for 10 cases of X SKU is transmitted to an operator.

• The operator receives his instruction via his headset and collects the 10 cases of X SKU.
• To complete this task he reports through his portable microphone a pre-arranged phrase such as “Yes” or “Done”.
• The computer in the warehouse office captures the phrase and records the text “Yes” to the programme.
• The database reduces the quantity of X SKU by 10 cartons from the stock.

 
Benefits Of Voice

Order picking productivity usually improves by 10 to 20 percent because pickers’ hands and eyes' free operation speeds up the picking of SKUs. It also reduces all unnecessary movements/walks back to the assignment desk. The warehouse productivity is also improved by paperless picking because the work of printing and distributing picking lists or labels is mostly eliminated.

TIP - Difference between speech recognition & voice recognition:
Speech recognition is the method of capturing the voice to identify and to return what someone has spoken.
Voice recognition is a method of capturing the voice to identify the person that is speaking.

• Pick-To-Light

This system could be used for picking (collecting) or putting (placing) products as an alternative to manually picking or packing various SKUs within the warehouse area.
Its aim is mainly to electronically assist warehouse personnel to locate the pick or pack location of the specific SKU(s) by the flashing indicator light hence, enabling pickers/packers to work in a more efficient and effective way in their respective areas.
The devise is located at the bottom or on top of the bin, shelf or rack warehouse area to attract the attention of the picker or packer.

 The Methodology:

• The order is scanned and the quantity required is shown on the “display module”.  
• A light illuminates to prompt the operator to collect the specific SKU(s) from the respective location.
• The operator collects the exact quantity and then presses the “send” button at the bottom of the location to confirm transaction.
• Stock is updated “real-time”.   

Benefits From Pick-To-Light Technology

It provides additional speed and accuracy in the order processing. Pick-to-Light technology reduces the time required searching for the location or the correct SKU hence, it increases the picking or packing rate.

Pick-To-Light technology provides additional speed and accuracy in the order processing.

On the other hand, such technology is more relevant to small size SKUs placed in bins, or on shelves and not so applicable for big size SKUs placed on pallets (pallet load) or bulk stacking.

• Automated Storage & Retrieval Systems (AS & RS)

It is a computer-controlled robot type system for sorting, storing and retrieving
various SKUs (usually pallet loads) vertically or horizontally as it moves along fixed isles within the warehouse area.

It represents a much faster, reliable and most importantly accurate operation as the system doesn’t require human operator to function (unlike wise other MHE - forklifts etc).

Although such an application requires a large size - wide warehouse  areas for the business to get the full benefit of such technology, it is worth to mention the increasing demand for such automated systems in our today’s warehousing environment. 

AS & RS can significantly improve the warehouse productivity in many industries and not only in the Fast Moving Consumer Goods (FMCG).
(A few examples will include auto manufacturing, various paints and chemicals)


Benefits From AS & RS Technology
It can help increase productivity levels as the system can pick, replenish and sort SKUs without human operator’s intervention. Being constructed in modules it could be easy to adjust them in order to meet warehouse expansion plans. It also reduces labour costs and increases inventory accuracy levels.

• Pick-N-Go Order Selection

It is similar to pick-to-light selection as it enables the order picker to easier handle the fulfilment of the order and respond with speed and accuracy.
It is based on an automated fork lift process which can be provided from a variety of fork lift suppliers.

This system allows the warehouse picker and the automated fork lift to work together so, whenever a picker picks a case/unit there is always a fork lift readily available and waiting for him/her. In this way the picker’s productivity will increase substantially. It works as such:

• The WMS sends the customer order to the picker along with an automated fork lift.
• The picker receives the customer’s order via a pick by voice headset.
• At the same time the automated forklift loaded with a pallet is dispatched at the right place (following the picker) with its forks at the right height.
• The picker can now pick the assigned quantity of each SKU and places them on the top of the pallet.
• As the picker receives a new customer order the forklift automatically escorts the picker to the next location hence, enabling the picker to pick instead of driving the forklift.
• When the pallet on the forklift gets loaded, the system dispatches a new pallet to the picker and the loaded pallet is automatically driven to the dispatch area.

   
Benefits From Pick-N-Go Order Selection Technology
It is hands’ free process, which increases the picker’s flexibility in the warehouse. It also minimises the picker’s time spent in searching for the correct SKU or moving front and back to the warehouse office to collect/deliver orders. The picker continues working in his designated warehouse area never leaving his picking area.

The Pick-N-Go system is compatible with most forklift brands. It removes unproductive steps in the Warehouse business environment. It increases substantially the productivity rate.  

In this fast moving and ever demanding environment, for one to be ahead of the game, one has to be not only familiar with the current warehouse developments, but to be able to constantly and continually upgrade his knowledge with current and advanced trends in order to provide the expected service level and be able to contribute to the optimisation of his company’s performance.