SUMMER 2023

172
THE DISTRIBUTOR’S LINK
ROBERT FOOTLIK HIGH PERFORMANCE DISTRIBUTION UPDATE from page 170
Order Checking
Checking no longer will follow the ancient format of
one person to pick, another to check and a third individual
to pack the orders. If the pickers can be trusted to get
the order right the first time, as continuously verified by
the computerized system, then the goods can be placed
directly into the shipping carton. This saves many steps
and eliminates errors at every point.
AI statistical sampling of the output is then employed
to verify quality and determine areas where additional
training or programming may be required. A 4% sample of
completed, sealed orders can be cut open and the contents
checked as though the inspector was a customer. The goal
is not to find errors but to verify perfection. Any mistakes
encountered are logged with an AI program looking for
patterns to form a curriculum for future training sessions
while simultaneously providing the real time feedback
that an individual needs to do their job better. Using this
technique provides a statistical guarantee with 97+%
confidence that the conditions encountered are applicable
to all the orders. This is well above the results of a typical
“two heads are thicker than one” approach.
Other Applications
The hands-free, paperless warehouse environment is still
an evolving technology. Customization and updating of the
Warehouse Management System can be accomplished using
programming without affecting the layout and equipment.
Nevertheless, it is always best to synchronize the hardware,
software and training to encourage synergy. As RFID and
AI come on line, the technology will replace or complement
existing systems to create even greater efficiency.
The end result is flexibility to accommodate a wide
variety of customer needs, employee skills and training
requirements while providing stunning improvements in
accuracy, productivity, employee morale, and customer
satisfaction all the way to the final user of the products
you sell and deliver.
Is All This Going To Be Accepted By
The Staff And Union?
With this level of detail, the system can also provide
a running database of the time spent at each task;
orders completed against orders to be processed; and
individual/team productivity for an incentive based pay
system. Preset limits can also be used to notify the
pickers and/or management of impending situations such
as a temporary need for more pickers or an anomaly that
requires some immediate attention.
Under mutual trust conditions the staff can be empowered
to make more decisions regarding their output and work at
their own individual pace in a collaborative manner. If the error
rate noted in subsequent operations rises the system can be
programmed to add more prompts or slow down to help the
worker improve accuracy. This provides immediate feedback
for both the personnel and management.
Continuous monitoring by management is definitely
going to be problematic in an antagonistic environment!
Resolving labor/management and privacy issues is an
evolving reality. Lawyers and mediators are going to be
quite busy.
Send In The Cobots And Robots
Not quite ready for prime time usage by a Fastener
Distributor is a fully robotic warehouse. The equipment,
visual and physical locating systems, combined with
mobile autonomous electronic/mechanical workers is
still a distant dream. “Cobots” that work with human
partners, however are closer and more affordable. At the
simplest level, a powered pallet mover can operate on a
wireless “leash” to follow a picker as they move through
the warehouse. Upon order completion, the vehicle can be
directed autonomously to the dock or to another worker
as a replacement vehicle is dispatched. This requires
a high level of sophistication for the equipment, but for
the human it is no different from being followed by a
particularly useful puppy.
Is All This Practical And Affordable?
Not yet, but the future is moving closer. As
automobiles, trucks and people movers proliferate the
sensors and AI programs have dropped in price, improved
in accuracy/safety and gained wider acceptance. Planning
for the technology requires only a little time, effort and
capital. The wise Fastener Distributor will be watching and
implementing to stay ahead of competition while providing
improved service, accuracy and reliability.
ROBERT FOOTLIK