{"id":9793,"date":"2021-09-28T08:48:39","date_gmt":"2021-09-28T15:48:39","guid":{"rendered":"https:\/\/www.qad.com\/blog\/?p=9793"},"modified":"2021-09-28T08:50:18","modified_gmt":"2021-09-28T15:50:18","slug":"3-invisible-forces-blocking-efficient-material-handling","status":"publish","type":"post","link":"https:\/\/www.qad.com\/blog\/2021\/09\/3-invisible-forces-blocking-efficient-material-handling","title":{"rendered":"3 Invisible Forces Blocking Efficient Material Handling"},"content":{"rendered":"

[vc_row][vc_column][vc_single_image image=”9794″ img_size=”full”][vc_column_text]Growing up I had this recurring dream, where I\u2019m trying to climb the basement stairs at home, but I can\u2019t quite reach the top, as there is this invisible force holding me back – creepy! What was holding me back? And, why couldn\u2019t I see it? Though I may never truly understand the meaning behind my dream, the idea of invisible or unknown forces impacting manufacturing operations is not new. When it comes to efficient material handling, specifically, numerous companies have experienced this sort of dream as reality.<\/span><\/p>\n

A Common Data Collection Misconception<\/span><\/h2>\n

In manufacturing operations, we are all trying to reach that next step in efficiency and process gains, but there are forces we might not see that can hold us back. Most companies have been using RF Data Collection for decades, but could it be that your current solution is the Great Invisible Oz behind the curtain holding you back? Data Collection after all is nothing more than barcode scanning and real-time data capture, and that enables increased transaction accuracy, right?<\/span><\/p>\n

Yes, but that\u2019s not all it can be, nor is that all it enables. Even though we are electronically capturing data, are we also electronically directing?<\/span><\/p>\n

Visual, Verbal, Paper based communications <\/span><\/i>to direct material handlers on what to pick and where to put material away, is the hallmark of the first invisible force. Are you using Excel spreadsheets to schedule production? Are your shipping schedule picklists printed? Are your material handlers visually checking work cell locations if they require more materials?\u00a0 If your answer to these questions are \u2018Yes\u2019, perhaps your system applications aren\u2019t set up to handle a digital-forward approach – which could be fueling the following forces.<\/span><\/p>\n

Lack of Full System Integration<\/span><\/h2>\n

If your Data Collection solution is not providing <\/span>digital<\/b> based pick\/pack\/putaway instructions, then it\u2019s not integrated with your production scheduling and logistics system. Having a <\/span>lack of full system integration<\/b> can create an invisible force that negatively impacts material handling efficiency. In a recent QAD webinar \u2014 <\/span>Materials Management Best Practices During a Labor Shortage<\/span><\/a> \u2014 we illustrate a case study demonstrating how an <\/span>integrated production scheduling system<\/span><\/a> enables <\/span>digitally directed<\/b> material putaway and production material replenishment.<\/span><\/p>\n

The primary value-add of material handlers is to unpack, move and pack materials. The \u201cdata collection \/ capturing of data\u201d aspect of the receiving, move, pick\/pack processes, is that value add or is it overhead?<\/span><\/p>\n

A Life Sciences customer once told me, <\/span>\u201cI need to know in terms of minutes of accuracy, how long this material has been outside of cold storage to identify spoilage. Barcode scanning is essential to gather this information accurately – the more data collected the better.\u201d <\/span><\/i>On the other hand, an Automotive parts manufacturer told me, <\/span>\u201cEvery data entry keystroke required by my users is time away from the operational activities I need them for.\u201d<\/span><\/i> What I took away from these customers is that the value-add of collecting data can make the difference between spoiled or sellable products, while at the same time must be accomplished in the most streamlined manner.<\/span><\/p>\n

Lack of Automation<\/span><\/h2>\n

This brings us to the second invisible force – having a <\/span>lack of automation<\/b>. We don\u2019t have our material handlers so they can be data entry clerks, but on the other hand, collecting inventory transactions is critical for inventory control and traceability. If we could get to a \u201csingle scan\u201d receipt or two-scan transfer, over the course of hundreds of transactions a day, how much time could be saved, and how many errors could be avoided?<\/span><\/p>\n

In the case of the traceability of temperature sensitive material, for example, we could eliminate the barcode scan through RFID automation. Having a technology and systems framework, such as <\/span>QAD Automation Solutions<\/span><\/a>, that allows you to \u201cautomate\u201d aspects of the data collection processes through external technologies like RFID, temperature monitors and motion sensors is vital.\u00a0\u00a0<\/span><\/p>\n

Lack of System to Process Alignment<\/span><\/h2>\n

The greatest invisible force is having a <\/span>lack of system to process alignment<\/b>. When you train your employees on using your Data Collection system, it might go something like this: \u201c<\/span>To prepare for a customer shipment to pick\/pack\/print labels, you first go to this screen option 1, then you go to that screen option 2, and then that one, but only that one in case of XYZ, and when you finished all of that you go that that option to print your labels.\u201d<\/span><\/i> Doesn\u2019t that sound like a process workflow of a back office ERP system?<\/span><\/p>\n

To achieve peak material handling efficiency, you need to have the ability to align the system to the process, versus aligning the process to the system. This was the case with <\/span>Hendrickson<\/span><\/a>, a global manufacturer and supplier for the commercial transportation industry. Hendrickson were able to achieve a 40% improvement in material handler efficiency with reduced wait times at both shipping and work centers. They also saw a 30% improvement in shipment packer efficiency and 60% improvement in material handler efficiency.<\/span><\/p>\n

For most legacy Data Collection solutions today, if some process automation and alignment is achieved, it\u2019s through expensive, hardcoded customizations. Each time you want to change or further automate, it becomes more expensive and more rigid, to a point where it becomes a barrier to achieving anything more. Material Handling solutions that are bent through hardcoding is yet another hidden force holding you back.<\/span><\/p>\n

Achieving Efficient Material Handling \u201cat the Top of the Stairs\u201d<\/span><\/h2>\n

With your current Data Collection solution, where are you on your stairs?<\/span><\/p>\n