News
Removing picking errors with a voice-based solution
31.08.2009
TINE Meieriet Øst Sem, which began using a voice-based solution from Consafe Logistics last autumn, has reduced picking errors by 90%.
“The success of the pilot project means that we will install the solution in our 22 other production and storage facilities throughout Norway during 2010,” says Glenn-Ove Forsland, System Consultant for Industrial IT at TINE.
This emerged at a seminar held by Consafe Logistics for industry operators in Tønsberg in the early summer. TINE Meieriet Øst Sem outside Tønsberg, one of the company’s largest picking warehouses in Norway, chose the solution from Consafe Logistics to enhance the efficiency of the logistics routines in the warehouse. Picking was previously done using paper lists and crossing items off. After the introduction of voice-controlled picking, the manual routines have been replaced by an electronic voice-based pick list that is transferred from their ERP/WMS system to the clerk’s ear via a headset and microphone. The system specifies which goods are to be picked and where they are located in the warehouse.
Robust warehouse administration tool
Tine Meieriet Øst Sem invited tenders last year and ten suppliers submitted competing tenders for the order. Factors such as price, quality, flexibility and robustness meant that Consafe Logistics won the contract. A close partnership with TINE ICT began last autumn. Glenn Ove Forsland in the department prepared a warehouse administration tool that ensures that orders entered in Movex are forwarded to the Consafe Logistics system. It converts the orders into a voice-based pick list that is transferred to the clerks’ ears via headsets. “The Consafe Logistics solution has an open user interface that can easily be integrated with our business system and systems we have developed ourselves,” he points out. Alen Ombasic, Returns and Service Manager at TINE Meieriet Øst Sem, praises the good cooperation with the employees, the ICT department at TINE and Consafe Logistics. “Everyone contributed to adapting the solutions to the users’ requirements.”
Small-scale tests
The pilot project for voice-based solutions started in summer 2008. Working groups were set up and a work schedule was drawn up. During the autumn, small-scale tests of the solution were conducted in the warehouse with pairs of employees. “Superusers were appointed to be responsible for training the other employees up to the end of October/November,” says Ombasic. He explains that the project was put on ice until after New Year for fear of instability in connection with Christmas celebrations. “The project has now been fully tested and approved by us. This means that the voice-based solution will be implemented at TINE’s 22 other sales dairies in the first half of 2010 in good time before an upgraded version of Movex is in place. Forsland explains that the old WMS system is now being replaced by a WMS solution developed inhouse in cooperation with Consafe Logistics.
Optimising warehouse processes
TINE previously used manual pick lists to pick products in the warehouse. When the products had been shipped, the pick lists were delivered to the shipping office, which processed them manually before invoicing. The warehouse management routines have been simplified with today's voice-based picking. The solution also includes automatic invoicing which we are considering implementing in the autumn,” says Forsland. He adds that all 45 employees in the warehouse have their own voice profile. “It used to take nearly 14 days to train our temporary employees in our picking routines. With the new system, this operation takes two hours.”
Less sick leave
“What results have you achieved by reducing picking errors by 90%?”
“The reduction in picking errors has resulted in greater satisfaction in the customer base and has generated a considerable reduction in operating costs. Among other things, this reduces the need for extra deliveries to our customers. We have also phased out two positions as checkers since the New Year as a result of the reduction in picking errors. The wastage percentage has also fallen dramatically and HSE has been reinforced. The employees have their hands and eyes free and work at the correct working height. The result is fewer strain injuries and less sick leave. In the long term, this will enhance the efficiency of the warehouse,” says Ombasic.
No negative impact on well-being
“How has the solution affected the well-being of the employees?”
“The system is very user-friendly and pickers can stop picking at any time, pause the system and take a break as they need without this resulting in them having to work harder. The social environment is therefore in good shape,” says Ombasic. He explains that the use of voice-based picking will increase productivity by approximately 25% and improve accuracy by approximately 99.99%. “Within 6-12 months, the investment will have been recouped,” he concludes.
