SmartTurn Inventory and Warehouse Management Best Practices Series
If your operation is one of the tens of thousands of warehouses in the United States still using paper, Microsoft Excel, or processes first developed in the late 70s/early 80s, we’re here to help. To give you tools, information, guidance, tips, proven methodologies, we offer you the forthcoming "Best Practice Series for Inventory and Warehouse Management."
If your operation is one of the tens of thousands of warehouses in the United States still using paper, Microsoft Excel, or processes first developed in the late 70s/early 80s, we’re here to help. To give you tools, information, guidance, tips, proven methodologies, we offer you the forthcoming "Best Practice Series for Inventory and Warehouse Management."
Best Practices for Setting up a Warehouse RF Network
Posted 08-10-2009 at 03:47 PM by Kevin Collins
Best Practices for Setting up a Warehouse RF Network
Introduction
Why go wireless? Consider that more than one in five wholesale distribution employees work in the warehouse. Some companies have saved hundreds of thousands of dollars in annual labor costs (through both full-time and seasonal labor savings) after implementing an RF (radio frequency) network.
In the previous Best Practice chapter (Best Practices for RF Mobile in 3PL and Warehousing Operations), we looked at the business rationale for implementing an RF network in a 3PL or warehouse operation. The opportunity to save on labor alone makes RF worthwhile. In addition to labor reduction, we looked at many other benefits, arguing (a position already clearly shared by thousands of companies) that the pros for moving forward with RF far outweigh the cons. In this chapter, we're going to look at the actual implementation process. How do you actually replace paper with RF? What do you need to think about? What are some of the gotchas that can trip up an implementation project?
A final comment before we begin; depending on the size and sophistication of your company, you'll want to make the RF implementation a cross-functional project. Don't expect (or allow) one part of the company to own it. Create a cross-functional team to determine the overall plan, chose the appropriate technology and manage everyone's expectations. Select someone from outside IT as team head.
Seeing the Big Picture: an inventory of your warehouse and equipment
One level down from the big picture is the warehouse. (For the purposes of this discussion, we'll assume a project to install a RF network in one medium sized warehouse).
Your Warehouse Layout
Barcode systems are heavily transaction-oriented and any connectivity interruption can produce data loss and error. In the typical warehouse, there are many ways that bar codes can be scanned and there are countless potential obstructions (from walls and poles, to metal and operating temperature) that can attenuate wireless signals. Warehouse layout and your choices in providing RF coverage within this space will dramatically affect transmission consistency and reliability. A wireless implementation project, therefore, begins with an analysis of warehouse design and layout, in which system designers obtain information on coverage, equipment placement, power considerations and wiring requirements to ensure that RF signals remain accessible to warehouse employees.
Rack Flexibility and Density
When deploying a wireless LAN within a warehouse, you'll likely run into RF coverage problems, many of which will be due to racking. Racking (materials, placement, and density, etc) is in fact the biggest issue with warehouse RF. Metal shelving racks (as well as metal support beams and the continually changing numbers of items on racks) reduces radio signal propagation and pattern consistency, decreasing reads and accuracy. As the number of items on shelves constantly changes, coverage holes may be created or closed, producing sporadic connectivity loss that can seriously frustrate employees.
The more packed together the racks, the harder it will be to propagate clear signals to every point a barcode scanner could be used. The more pallets you store, the more (meaning closer) access points you'll have to install. A density of one pallet every six square feet obviously requires more wireless access points than a density of one pallet every eight square feet.
The easiest way to address coverage holes and ensure full coverage in all warehouse areas is to install additional access points. Additional help can come from having a flexible rack layout in which you can modify pick levels and locations.
What barcodes are you going to use? Barcode is a long-established technology and standards exist. Although most handheld scanners can read multiple barcode symbologies, it is still important to coordinate and confirm with your warehouse management system (WMS) vendor (and your customers) that everything "from the scanners and barcodes, to the printers and WMS" is compatible.
Selecting the right technology depends on many factors, ranging from your budget, to the type of lift equipment you use. You need to consider the work environment and what you really need. Spend some time at difference hours of the workday in the warehouse to observe how employees do their jobs currently and how they will likely do them when equipped with RF scanners. Here are some of the issues to consider:
Handheld Scanners
These are battery powered and carried or worn by employees who move frequently, either on foot or riding some kind of lift vehicle.
Hands-free Scanners
These devices are worn on the arm or around the waist, freeing the employee to work. A common task when wearing these is picking. Scanners worn on the arm are usually equipped with a screen and keyboard.
Mounted Scanners
Vehicle scanners are powered by the vehicle's electrical system, usually more robust, harder to drop or damage and certainly harder to steal. They are appropriate when the operator remains close to the forklift but you do lose the flexibility to pick from the floor. RF scanners can be mounted on forklift trucks for pallet movement with handheld units for on-foot transactions e.g. inventory, picking and cycle counting etc.
You're probably very familiar with Wi-Fi networks, either at work or at home. Networking access points are very similar to the wireless router in your home. Designed for installation on shelves, ceilings (the most common location in warehouses) or walls, access points connect the network of RF scanners or terminals to the wired physical computer network. The backhaul to the central database is enabled through a hard wired connection.
Industrial versions are typically ruggedized with sealed enclosures to protect against environmental threats such as dirt, moistures and chemicals. They are designed to deliver reliable connectivity with interference avoidance, as well as coexist with other RF networks. Multiple access points can be overlapped to ensure full coverage of the warehouse layout, penetration of obstacles and high-speed roaming.
What type of network will work best for your situation? You're going to want a spread spectrum or wide band system network. There are a number of frequency options (900MHz, 2.4.GHz and 5GHz). You can use centralized or distributed architecture and you'll undoubtedly use some flavor of the 802.11 standard.
RF-based 802.11 standards dominate the current installed base of wireless LANs. Regardless of which kind (a/b/g/n) you use, they each provide sufficient data transfer speed for most RF data capture applications in warehouses and distribution centers.
Spread Spectrum Technology
Spread spectrum or wide band system operate in a variety of bands (902-928 MHz, 2.4-2.48 GHz, and 5.725-5.850 GHz). These medium range (100 to 1,000 feet) systems are significantly faster than narrow band transmissions, with the 2.4 GHz systems offering comparatively greater bandwidth and support for higher data rates exceeding 11 Mbps.
Security
You can't discuss wireless networking without a few words about security. Not everything accessible through your wireless network is a corporate secret. You must evaluate what needs to be protected and to what level it needs to be protected. You need to understand system and security vulnerabilities. A competent systems integrator can help you with an initial evaluation, after which a good network security administrator can maintain and update the security protections you've selected. Numerous third-party firewall, encryption and authentication products can be used in conjunction with 802.11-standard technology.
RF Testing/Site Surveys
The number of access points you deploy should be based on a site survey or test (and not your intuition or best guess). A site survey is an RF study to determine whether a warehouse has unusual interference issues. Testing will confirm how signals behave inside your facility’s concrete walls and steel doors. It serves as a guide for the network design, installation and verification of the wireless communication infrastructure, and helps you calculate your equipment needs.
Who is going to do it?
Who is actually going to do all of the work? Who should design the system? Is it worth your time to sufficiently educate yourself about RF technology to implement a system yourself? Do you have someone on your staff that can do it? Is your brother-in-law an expert? Most businesses concentrate on running their businesses and lack the time, personnel and expertise to handle an RF installation project. A commonsense response is to find a technology solutions provider or systems integrator focused on the 3PL or warehouse industries that has a deep understanding of RF technology. If you're going to look for an outside vendor, look for a knowledgeable IT and data wiring vendor. Look for someone who can design a system (and provide you in advance with a nice CAD drawing of the project) and procure the necessary hardware and software, including IDF cabinets, access points, and cabling needs. (It almost goes without saying) that they should know the specs and operating ranges of every piece of recommended equipment. You might want to do some research with companies in your area that have already made the wireless jump and investigate any vendors they recommend. Avoid vendors that just want to sell you hardware.
Although implementing an RF system probably represents less work than other potential warehouse process changes such as cross docking or an automated sortation system, you might want to start slowly. You don't have to bite off everything at once. Instead, you can deploy RF progressively, starting with one function or area, such as the receiving dock to welcome incoming shipments. Eventually, and probably faster than you can imagine, you can expand RF to the other areas of your warehouse. Of course, the alternative is true; you can just jump right in and do everything at once.
Is your WMS RF-enabled?
You are using a WMS, aren't you? Does it support input from RF terminals, or does it only interface with wired devices? Barcode systems are transaction-dependent. Connectivity loss during a transaction can cause errors. Depending on the WMS programming, sporadic connectivity may or may not be a problem.
The vision of a wireless warehouse is already here. It may take a leap of faith on your part to envisage your warehouse being RF-enabled but there is no reason why your workday can't take place amid RF communication, automated data capture, handhelds and lift truck-mounted RF scanners, and streamlined shipping and receiving procedures. Shipments will arrive, becomes part of your inventory and then be shipped out seamlessly. RF tracking will almost eliminates paper in the warehouse.
When your WMS and wireless are working happily together, paper doesn't necessarily become completely extinct but every quarter, you should be ordering increasingly fewer reams, pens and pencils. The WMS will help you direct and manage the picking, packing and shipping processes. Picking directions and data will be distributed to warehouse personnel on their mobile devices. Without having to return to the office to pick up directions, employees will receive the necessary information to know where to go, what to pick, how many to pick and what to do with it.
Here is how this picture might look: your network backbone is a wireless local area network (with 802.11 connectivity) that utilizes a sufficient number of wireless access points spread out over the facility. The employees have been appropriately trained to use the handheld scanners and lift-truck mounted devices. Information is distributed quickly to the warehouse floor. Things get done. You make more money. You even get a raise.
Conclusion
Incorporating RF into your warehouse operation may seem daunting, but the benefits should considerably exceed any perceived risks. Most, if not all, of the leading companies in the 3PL and warehousing industries already use RF networks in their warehouse and distribution centers. This is proven technology with well documented benefits. With proper preparation, and smart decisions about vendor support and technology, your company and customers should love the results.
Kevin Collins,
Director, Product Management
SmartTurn, Inc.
177 Fremont St.
San Francisco, CA 94105
USA
Sales: 1-888-667-4758
Tel: 1-415-685-4200
Fax: 1-415-685-4201
About SmartTurn
SmartTurn™ Inventory and Warehouse Management System is the first true on-demand warehouse management system to provide enterprise class functionality at a fraction of the cost of traditional license and install software. Designed for quick implementation, ease-of-use, real-time inventory accuracy and warehouse performance, the SmartTurn system provides visibility on every item across single or multiple warehouses. Founded on the premise that software should be smart, simple and safe, SmartTurn’s customers span the value chain of most industries to include manufacturers, wholesalers as well as 3PLs. SmartTurn is privately held and backed by leading investors, NEA and Emergence Capital Partners. Website www.smartturn.com
About the Author
Mr. Kevin Collins joins SmartTurn having been in the warehousing and distribution business for over 15 years, where he fulfilled leadership roles for a military distribution company, a third party logistics service provider, a heating, ventilation and air conditioning company, a retail service warehouse and a general merchandise/wholesale grocery warehouse where he also partook in two acquisitions. Mr. Collins has spent his entire career learning the art of warehousing and logistics, and has been in every conceivable role within a warehouse. During his career span, Mr. Collins has also had the privilege of working directly with application developers learning about software from inventory and procurement to transportation and warehouse management systems. Mr. Collins brings to SmartTurn an invaluable background and information about processes, software and logistics, and the intricate balances between them.
Introduction
Why go wireless? Consider that more than one in five wholesale distribution employees work in the warehouse. Some companies have saved hundreds of thousands of dollars in annual labor costs (through both full-time and seasonal labor savings) after implementing an RF (radio frequency) network.
In the previous Best Practice chapter (Best Practices for RF Mobile in 3PL and Warehousing Operations), we looked at the business rationale for implementing an RF network in a 3PL or warehouse operation. The opportunity to save on labor alone makes RF worthwhile. In addition to labor reduction, we looked at many other benefits, arguing (a position already clearly shared by thousands of companies) that the pros for moving forward with RF far outweigh the cons. In this chapter, we're going to look at the actual implementation process. How do you actually replace paper with RF? What do you need to think about? What are some of the gotchas that can trip up an implementation project?
A final comment before we begin; depending on the size and sophistication of your company, you'll want to make the RF implementation a cross-functional project. Don't expect (or allow) one part of the company to own it. Create a cross-functional team to determine the overall plan, chose the appropriate technology and manage everyone's expectations. Select someone from outside IT as team head.
Seeing the Big Picture: an inventory of your warehouse and equipment
One level down from the big picture is the warehouse. (For the purposes of this discussion, we'll assume a project to install a RF network in one medium sized warehouse).
Your Warehouse Layout
Barcode systems are heavily transaction-oriented and any connectivity interruption can produce data loss and error. In the typical warehouse, there are many ways that bar codes can be scanned and there are countless potential obstructions (from walls and poles, to metal and operating temperature) that can attenuate wireless signals. Warehouse layout and your choices in providing RF coverage within this space will dramatically affect transmission consistency and reliability. A wireless implementation project, therefore, begins with an analysis of warehouse design and layout, in which system designers obtain information on coverage, equipment placement, power considerations and wiring requirements to ensure that RF signals remain accessible to warehouse employees.
Rack Flexibility and Density
When deploying a wireless LAN within a warehouse, you'll likely run into RF coverage problems, many of which will be due to racking. Racking (materials, placement, and density, etc) is in fact the biggest issue with warehouse RF. Metal shelving racks (as well as metal support beams and the continually changing numbers of items on racks) reduces radio signal propagation and pattern consistency, decreasing reads and accuracy. As the number of items on shelves constantly changes, coverage holes may be created or closed, producing sporadic connectivity loss that can seriously frustrate employees.
The more packed together the racks, the harder it will be to propagate clear signals to every point a barcode scanner could be used. The more pallets you store, the more (meaning closer) access points you'll have to install. A density of one pallet every six square feet obviously requires more wireless access points than a density of one pallet every eight square feet.
The easiest way to address coverage holes and ensure full coverage in all warehouse areas is to install additional access points. Additional help can come from having a flexible rack layout in which you can modify pick levels and locations.
What Bar Codes Are You Using?TIP: your access points will probably be staggered throughout the building on about 100 ft to 150 ft centers depending on rack density.
What barcodes are you going to use? Barcode is a long-established technology and standards exist. Although most handheld scanners can read multiple barcode symbologies, it is still important to coordinate and confirm with your warehouse management system (WMS) vendor (and your customers) that everything "from the scanners and barcodes, to the printers and WMS" is compatible.
The Technology Sequence: selecting what is right for you
Selecting the right technology depends on many factors, ranging from your budget, to the type of lift equipment you use. You need to consider the work environment and what you really need. Spend some time at difference hours of the workday in the warehouse to observe how employees do their jobs currently and how they will likely do them when equipped with RF scanners. Here are some of the issues to consider:
- Do workers were gloves?
- Do employees need to have a keyboard to enter data? (How much data will they have to enter?)
- How large do the scanner keys need to be?
- Will you need scanners that can resist abrasion and contact with chemicals?
- Will you need scanners that are moisture or anti-fog proof?
- Will the scanners need touchscreens?
- Will they be used in direct sunlight? Can screens be read at different times of the day?
- How important is processor speed? Are you willing to trade off faster processor speed for shorter battery life?
When it comes to scanners, you essentially choose among three types: handheld, hands-free and vehicle-mounted.
Handheld Scanners
These are battery powered and carried or worn by employees who move frequently, either on foot or riding some kind of lift vehicle.
Hands-free Scanners
These devices are worn on the arm or around the waist, freeing the employee to work. A common task when wearing these is picking. Scanners worn on the arm are usually equipped with a screen and keyboard.
Mounted Scanners
Vehicle scanners are powered by the vehicle's electrical system, usually more robust, harder to drop or damage and certainly harder to steal. They are appropriate when the operator remains close to the forklift but you do lose the flexibility to pick from the floor. RF scanners can be mounted on forklift trucks for pallet movement with handheld units for on-foot transactions e.g. inventory, picking and cycle counting etc.
Wireless Access Points
You're probably very familiar with Wi-Fi networks, either at work or at home. Networking access points are very similar to the wireless router in your home. Designed for installation on shelves, ceilings (the most common location in warehouses) or walls, access points connect the network of RF scanners or terminals to the wired physical computer network. The backhaul to the central database is enabled through a hard wired connection.
Industrial versions are typically ruggedized with sealed enclosures to protect against environmental threats such as dirt, moistures and chemicals. They are designed to deliver reliable connectivity with interference avoidance, as well as coexist with other RF networks. Multiple access points can be overlapped to ensure full coverage of the warehouse layout, penetration of obstacles and high-speed roaming.
Networking considerations
What type of network will work best for your situation? You're going to want a spread spectrum or wide band system network. There are a number of frequency options (900MHz, 2.4.GHz and 5GHz). You can use centralized or distributed architecture and you'll undoubtedly use some flavor of the 802.11 standard.
RF-based 802.11 standards dominate the current installed base of wireless LANs. Regardless of which kind (a/b/g/n) you use, they each provide sufficient data transfer speed for most RF data capture applications in warehouses and distribution centers.
Spread Spectrum Technology
Spread spectrum or wide band system operate in a variety of bands (902-928 MHz, 2.4-2.48 GHz, and 5.725-5.850 GHz). These medium range (100 to 1,000 feet) systems are significantly faster than narrow band transmissions, with the 2.4 GHz systems offering comparatively greater bandwidth and support for higher data rates exceeding 11 Mbps.
Security
You can't discuss wireless networking without a few words about security. Not everything accessible through your wireless network is a corporate secret. You must evaluate what needs to be protected and to what level it needs to be protected. You need to understand system and security vulnerabilities. A competent systems integrator can help you with an initial evaluation, after which a good network security administrator can maintain and update the security protections you've selected. Numerous third-party firewall, encryption and authentication products can be used in conjunction with 802.11-standard technology.
RF Testing/Site Surveys
The number of access points you deploy should be based on a site survey or test (and not your intuition or best guess). A site survey is an RF study to determine whether a warehouse has unusual interference issues. Testing will confirm how signals behave inside your facility’s concrete walls and steel doors. It serves as a guide for the network design, installation and verification of the wireless communication infrastructure, and helps you calculate your equipment needs.
Make RF testing as realistic as possible. Don't think of testing as a single point in time prior to submitting your initial equipment order. To ensure that RF coverage meets your needs (and the changing realities of your warehouse operations), consider regular testing. What is regular? Twice a year tests in which you measure RF scan performance (particularly) low to the ground near the lowest shelves.
Things (and a few Gotchas) to Think About
Who is going to do it?
Who is actually going to do all of the work? Who should design the system? Is it worth your time to sufficiently educate yourself about RF technology to implement a system yourself? Do you have someone on your staff that can do it? Is your brother-in-law an expert? Most businesses concentrate on running their businesses and lack the time, personnel and expertise to handle an RF installation project. A commonsense response is to find a technology solutions provider or systems integrator focused on the 3PL or warehouse industries that has a deep understanding of RF technology. If you're going to look for an outside vendor, look for a knowledgeable IT and data wiring vendor. Look for someone who can design a system (and provide you in advance with a nice CAD drawing of the project) and procure the necessary hardware and software, including IDF cabinets, access points, and cabling needs. (It almost goes without saying) that they should know the specs and operating ranges of every piece of recommended equipment. You might want to do some research with companies in your area that have already made the wireless jump and investigate any vendors they recommend. Avoid vendors that just want to sell you hardware.
You can start slowly
Although implementing an RF system probably represents less work than other potential warehouse process changes such as cross docking or an automated sortation system, you might want to start slowly. You don't have to bite off everything at once. Instead, you can deploy RF progressively, starting with one function or area, such as the receiving dock to welcome incoming shipments. Eventually, and probably faster than you can imagine, you can expand RF to the other areas of your warehouse. Of course, the alternative is true; you can just jump right in and do everything at once.
Is your WMS RF-enabled?
You are using a WMS, aren't you? Does it support input from RF terminals, or does it only interface with wired devices? Barcode systems are transaction-dependent. Connectivity loss during a transaction can cause errors. Depending on the WMS programming, sporadic connectivity may or may not be a problem.
NOTE: you’ll need a WMS with wireless capabilities to maximize the benefits of real-time access to shipping and inventory data.How it Works When it is Working
The vision of a wireless warehouse is already here. It may take a leap of faith on your part to envisage your warehouse being RF-enabled but there is no reason why your workday can't take place amid RF communication, automated data capture, handhelds and lift truck-mounted RF scanners, and streamlined shipping and receiving procedures. Shipments will arrive, becomes part of your inventory and then be shipped out seamlessly. RF tracking will almost eliminates paper in the warehouse.
When your WMS and wireless are working happily together, paper doesn't necessarily become completely extinct but every quarter, you should be ordering increasingly fewer reams, pens and pencils. The WMS will help you direct and manage the picking, packing and shipping processes. Picking directions and data will be distributed to warehouse personnel on their mobile devices. Without having to return to the office to pick up directions, employees will receive the necessary information to know where to go, what to pick, how many to pick and what to do with it.
Here is how this picture might look: your network backbone is a wireless local area network (with 802.11 connectivity) that utilizes a sufficient number of wireless access points spread out over the facility. The employees have been appropriately trained to use the handheld scanners and lift-truck mounted devices. Information is distributed quickly to the warehouse floor. Things get done. You make more money. You even get a raise.
Conclusion
Incorporating RF into your warehouse operation may seem daunting, but the benefits should considerably exceed any perceived risks. Most, if not all, of the leading companies in the 3PL and warehousing industries already use RF networks in their warehouse and distribution centers. This is proven technology with well documented benefits. With proper preparation, and smart decisions about vendor support and technology, your company and customers should love the results.
Kevin Collins,
Director, Product Management
SmartTurn, Inc.
177 Fremont St.
San Francisco, CA 94105
USA
Sales: 1-888-667-4758
Tel: 1-415-685-4200
Fax: 1-415-685-4201
About SmartTurn
SmartTurn™ Inventory and Warehouse Management System is the first true on-demand warehouse management system to provide enterprise class functionality at a fraction of the cost of traditional license and install software. Designed for quick implementation, ease-of-use, real-time inventory accuracy and warehouse performance, the SmartTurn system provides visibility on every item across single or multiple warehouses. Founded on the premise that software should be smart, simple and safe, SmartTurn’s customers span the value chain of most industries to include manufacturers, wholesalers as well as 3PLs. SmartTurn is privately held and backed by leading investors, NEA and Emergence Capital Partners. Website www.smartturn.com
About the Author
Mr. Kevin Collins joins SmartTurn having been in the warehousing and distribution business for over 15 years, where he fulfilled leadership roles for a military distribution company, a third party logistics service provider, a heating, ventilation and air conditioning company, a retail service warehouse and a general merchandise/wholesale grocery warehouse where he also partook in two acquisitions. Mr. Collins has spent his entire career learning the art of warehousing and logistics, and has been in every conceivable role within a warehouse. During his career span, Mr. Collins has also had the privilege of working directly with application developers learning about software from inventory and procurement to transportation and warehouse management systems. Mr. Collins brings to SmartTurn an invaluable background and information about processes, software and logistics, and the intricate balances between them.
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