Mobile Warehouse Automation Optimization

Increased Accuracy = Elimination of Waste
Since the core premise of Lean manufacturing is continued process improvement, the ability to increase control of inventory with time-tested accuracy of bar coding generates increased accuracy, decreased errors, and therefore the elimination of waste.

Real-Time Data Entry
According to Garber, “The benefits of real time data entry with a Mobile Warehouse, empowers employees to capture data at the point of origination providing faster and more accurate inventory reporting.”

Value Add Matrix
While not part of any specific technology a Value Add Matrix will allow recognition of the current state of a warehouse operation as well as the a plan to reach a lean state. Detailed Process steps are categorized as either value added or non-value added. Non-value added items include inventory (WIP and backlog), delays (operate based), duplication, movement, defects, rework, checking, and lost opportunities.

Maximizing Flow eliminates waste in the value stream and only values work that adds value to the end product. The goal is to continuously increase the velocity with which value-added work flows through an enterprise by reducing delays, reducing setup time (context switch) and eliminating complexity. Lean optimized environments will always be simpler after the application of lean concepts than it was before.

Creating a Pull environment – caps the amount of WIP in the system, and ensures that processes are driven by actual demand. In a near to overcapacity environment, controlling the release of work into a work queue is equivalent to controlling the “gas pedal” on the lead time of a process. Garber suggests, “By regulating how work is released into job-specific work queues, companies can greatly reduce lead time variability, which is shown to lead to higher work efficiency in a near capacity environment. The relationship between amount of WIP and lead time is described by “Little’s Law”, a cornerstone of Lean understanding. Controlling WIP can also can increase velocity of cash flow by prioritizing inputs, and making sure that the higher value processes get priority.”

Warehouse management often serves as one of the most costly components of a growing organization. Centrally managing orders to reduce costs, automating the receiving and put-away process to improve productivity, achieving optimal inventory control, keeping customer commitments with error-free order fulfillment, integrating shipping operations, and increasing productivity with mobile computing are central to cost-containment and short-term ROI of mobile warehouse technology investments. While change is often difficult, a change in technology systems, processes, and culture need not be difficult for employees. Adoption of new lean solutions must be a central element of strategic planning and operations automation excellence.