Warehouse Engineers attended the Modex Conference looking for low-cost solutions to improve warehouse operations. As a previous warehouse manager, I understand traveling isn’t always an option because you have to get orders out the door. No reason to fret, Warehouse Engineers has you covered with 10 solutions to common warehouse problems.
Problem 1: Cycle counts
We’ve all been there… the quarterly cycle count or worse, the full annual. Ware eliminates the cycle counting dilemma. Yes, that’s right, Ware deploys fleets of drones, powered by machine learning, to perform cycle counts. Ware creates the software and analytics that lets the drones do the work, saving time and money.
Problem 2: Tracing orders
Ever had an order delayed by the rail or carrier? Me!!! I’ve been on the phone with the carrier asking where is my order?
Pallet Alliance developed a platform to track individual pallets from end to end of the supply chain with IoT connectivity. Intellipallets integrate with existing wooden pallets providing efficient tracking of shipments. Once the pallets become “intelligent” they provide information like transit location or stationary time. Now you will know when your order is stuck in a rail yard.
Problem 3: BOL Paperwork
Why does the customer call for the BOL that you can’t seem to find?
BOLs are a necessary evil. You must get the driver to sign for the order, then store the order for years. The process creates so much paperwork, and it’s even harder to track individual BOLs. I hate when the customer calls for a BOL from 3 months ago. The smart people at SMART BOL developed an automated solution for bill of lading signing and document retention. Yes, there’s an app for drivers to sign the BOL and the signature magically goes into the cloud.
Problem 4: Communication Boards
I’ve struggled with outlining a white board for daily huddles. The magnets are not straight, the markers start to fade. Sometimes I spent more time preparing for the meeting than the actual meeting itself. Visual Workplace is a source for Lean & 5S Supplies. They have great templates for KPI Tracking and daily huddles. Visual Workplace can also print dry erase board overlays for kaizen events and root cause analysis.
Problem 5: Workstations
We all know the value of 5S, “a place for everything, and everything in its place.” But what if you don’t have a place for everything? Literally, while you are setting tools in order, you are missing a place for a tool. With PioneerIWS, you can easily build a custom workflow to meet your needs. Their Flexturs can be transformed into mobile workstations, shelves, and packaging stations. Setting and Sustaining workstations are a lot easier with PioneerIWS.
Problem 6: Shifted Rail Cars
Ever been nervous about opening a boxcar? I’ve been there, crossing my fingers hoping that the pallets are still upright.
Of course, the pallets have shifted and spilled over. Have you ever seen a rail car full of spilled tomato paste, yuck! Shifted cars are a no win for everyone involved. Filing a claim with the rail line is so difficult, most people don’t bother. The rail always points the finger at the packaging and swears they never hump cars. Next time I have this problem, I’m calling Southern Bracing Systems (SBS) for a solution. SBS manufactures a patented Ty-Gard 2000® approved by the Association of American Railroads (AAR) to keep orders in tack. They also provide expert training for AAR-approved cargo securement equipment and cargo restraint systems uniquely designed to prevent damage in-transit.
Problem 7: Missing Labels
In wet or grimy conditions, labels just won’t last.
I’ve had to label entire warehouses: entry doors, ramps, racks, etc… Sometimes a label just doesn’t work. The Patmark 1533 provides a solution for quick, custom permanent applications. MarkinBOX is the world’s most compact portable marking machine system. Combined with a carbide pin, you can mark on a vast range of surfaces like racks and bins. I wish I had the Patmark 1533 when I 5S’d a battery storage room.
Problem 8: Data Overload
We’ve all heard the phrase “big data” but what do we do with it?
Big data creates value when leaders can make data-driven decisions. With all the data coming from the WMS, ERP, and time clocks, who has time to consolidate the data for reporting? Easy Metrics solves the big data problem by providing custom reports and KPIs for your team. I know tracking labor can be burdensome, at times requiring a full administrator. Easy metrics makes it easy for everyone.
Problem 9: Packaging Dimensions
Length, Width, Height…. And where is my tape measuring?
We’ve all had to answer those questions when preparing parcel for delivery. It’s so frustrating when you have a large or heavy box that you need assistance with to get all the dimensions. Sizensor designed an app to instantly capture parcel dimensions. Sizensor has a lot of benefits around the warehouse like planning a load diagram for new products. Consider how easy the app is to install and use, it’s a win.
Problem 10: Warehouse Space
We need more space.
No warehouse manager wants to tell their president or sales team those words. I’ve lead tens of projects to increase density and utilization. We go vertical, we consolidate, move things around, but sometimes just need more space. When you literally need to pop up a warehouse, ClearSpan is your solution. ClearSpan warehouses can be custom designs or turnkey solutions for the appropriate storage solution.
There you have it, ten solutions for common problems within a warehouse. I hope this information is useful and please share with your colleagues. Collaboration and networking is another benefit of attending conferences. All the companies listed above have great salespeople Warehouse Engineers interacted with. If these are great ideas, and you don’t have capacity to manage the project contact Warehouse Engineers. Brandon Ashby, the managing partner, is a certified Project Management Professional who can manage the project for you.
Author Brandon Ashby earned a BS in Industrial & Systems Engineering from the Georgia Institute of Technology. He holds an MBA concentrating in Project Management from the University of Georgia. As a Lean Six Sigma Blackbelt and certified Project Manager, Brandon has the tools to document and improve a process. His most important asset is his humble personality and approach to work. He relates to frontline associates and makes their work easier while benefiting the company.