​​3 Smart Ways to Boost Your Order Fulfillment Process​

​​This is the second of a four-part series examining logistics processes within distribution centers or e-commerce fulfillment facilities. In our last discussion, we explored opportunities to improve operational efficiency and increase throughput for inbound logistics. Today, we’ll focus on order fulfillment.

​Consumer shopping behavior has shifted towards more online channels - such as Buy Online Pickup in Store (BOPIS) and direct ship. Retailers with both a brick-and-mortar and online presence are feeling the strain, as many DCs are not well-equipped to handle high-volume, fast delivery, and single-item orders.  

​High-performance barcode readers and machine vision systems play an increasingly critical role in helping organizations meet the surge in demand by fulfilling orders more efficiently, accurately, and cost-effectively. Real-time performance feedback and image offload let operations teams quickly diagnose code reading issues and address problems earlier in the process.

​Here are three popular order fulfillment applications and Cognex’s solutions to common challenges.

​Improve pick accuracy through item verification

​Retailers and e-commerce organizations take pride in order accuracy, positive reviews, and delivering on their brand promise. Shipping incorrect items incurs costs, adds rework time, and can have negative impacts on a retailer’s reputation. One approach to minimizing or eliminating the shipment of incorrect items is to implement a verification process that is both efficient and accurate.

Verifying order contents without slowing down cycle times can be challenging, especially if complete item information isn’t available at every step in the process. Many organizations perform manual checks, either visually or by scanning the item label. This works if the code label is correct or volumes are low enough for visual verification. However, if the code is torn, smudged, or damaged, the information may not be captured correctly, if at all, and can affect the order quality. If this happens, operators either rely on the information on the label or give their best guess. This results in errors, rework, and additional shipping costs to rectify the situation.

One way to increase traceability throughout the order fulfillment process is by using a 3D + 2D inspection system, such as the Cognex 3D-A1000 Dimensioning System, to capture and compare package dimensional data with the barcode information before the item is fulfilled. This approach provides accurate item-level dimensions to properly categorize and verify the correct item, thereby improving order accuracy, reducing order cycle time, and minimizing the costs associated with incorrect shipments.​

​​Improve pick times and accuracy

​With the rapid rise in e-commerce, operations teams are seeking ways to increase throughput while maintaining quality. Typically, the choice is either to hire more operators or to find ways to increase the efficiency of existing operators. To avoid increased costs, most companies choose the latter.

However, improving efficiency can be a challenging task. Codes can be located on any side of the package or can be damaged during transport or handling. This means operators must manipulate the package and try several scans before getting a good read. Older technology, such as laser barcode scanners, is often unreliable when reading damaged codes. Handheld or ring scanners limit the operator to just having one hand free, which affects productivity. Plus, handheld scanning technology is almost inevitably associated with high rates of breakage, loss, or connectivity issues.

​Many companies have discovered the benefits of hands-free overhead barcode reading. Deploying a presentation scanning solution using fixed-mount barcode readers, such as the Cognex DataMan 280, mounted overhead, solves these challenges. Image-based barcode readers with advanced decoding algorithms offer an advantage over laser or line scan technology in successfully reading damaged, smudged, or distorted codes. The overhead scanning configuration enables operators to quickly scan codes from any orientation – including upside down, sideways, or at extreme angles of up to 85 degrees - thereby improving throughput and efficiency.

Ensure totes are routed to the right pick station and decrease order cycle times

​Distribution and fulfillment centers use high-volume conveyance to deliver ordered items in totes to pick stations located in different zones throughout the facility. To do this efficiently, barcode readers read codes on the sides of the cartons/totes that contain order information and route them accordingly. Due to constant use and rough handling, codes on totes can wear down and become smudged or damaged. If a code cannot be read, totes will not reach any picking station and will continue to recirculate, which adds rework time and cost. Typical laser scanning technology can’t always read damaged codes or give facility managers feedback when codes become unreadable, which can lead to more significant issues later.

​Specific tote-tracking solutions, such as the Cognex SLX-280D, provide a powerful barcode reading solution for zone routing systems. These types of readers use advanced algorithms and decoding technology to reliably read damaged or misaligned barcodes on totes, even in small egress situations, sending them to the correct pick station. In addition, these solutions read codes omnidirectionally and at high perspectives when totes are not aligned on the belt. Using image-based output and code quality metrics from these barcode readers enables tote labels to be graded, allowing smudged and damaged codes to be replaced before no-reads cause problems downstream.