With a WES , food professionals can track inventory or raw materials ( and any number of attributes , such as lot numbers , temperatures , etc .) throughout a product ’ s life cycle . The system logs the product ’ s every move until it is loaded onto a truck for delivery . This creates an audit trail of every person and piece of equipment that touched that inventory as well as every adjustment made along the way . But , tracking and tracing capabilities go beyond the product ’ s movement within the warehouse ’ s four walls . Utilizing its flexibility to interface with other software systems like enterprise resource planning ( ERP ) and host systems , a WES can also capture batch data from the growers and manufacturers and marry the data with the lot information created during processing . Then , the system carries that data throughout each subsequent step in the supply chain — from storage , to packaging , to transportation , to the retail store shelf .
Mitigating Recalls
How does a WES assist in the recall process ? With the data captured , food companies can quickly access detailed product information in real time . Therefore , if a product must be recalled , it is easy to search the system for a batch or lot with a particular UPC or SKU and pinpoint when it departed and to where . With this specific information , manufacturers can pull only the affected items from store shelves . There is no need to spend valuable time and money removing every single product — an extremely expensive and inefficient approach that often draws more negative attention to the issue at hand . For example , in 1982 , Johnson & Johnson famously spent $ 100 million pulling all Tylenol products from the shelves after discovering bottles containing cyanide . Although this was a precautionary action to ensure that all tainted products were off the market , Johnson & Johnson could have saved a great deal of money if it could have identified which lot contained tampered bottles and pulled just that lot .
It is also possible to link manufacturing data from a WES to a retailer ’ s point-of-sale system . A recall could be as simple and low key as an automatic phone call to alert those who purchased the item in question . Also , with reliable data and accurate audit trails , food manufacturers can prove compliance with safety regulations , like FSMA , and confidently give consumers peace of mind that they have withdrawn all affected products .
Integration with an AS / RS
While a WES can streamline manual materials handling efforts , it provides additional value when integrated with an automated storage and retrieval system ( AS / RS ). These robotic systems can optimally store layers and cases , with and without pallets , and rapidly retrieve them from inventory . In addition to a software system like a WES , an AS / RS comprises four components : a rack system to store product , a storage / retrieval machine ( S / RM ) running on a floor rail , a load-handling device or shuttle that moves product from the S / RM to the rack , and a conveyor system that moves goods to and from the AS / RS to the staging areas .
Compared to a conventional warehouse storage system , a high-density AS / RS allows warehouses to improve their space utilization so companies can store more products , more efficiently , in a smaller amount of space . For the food industry , the speed that an AS / RS moves products in and out of the warehouse prevents the spoilage of goods , like meat and dairy products . It also enables just-in-time ( JIT ) order fulfillment strategies , a methodology in which orders are brought out when needed instead of staged hours in advance . This attributes to keeping products fresh and safe , as perishable items are stored in their respective freezers until the truck arrives . In these cases , when the truck “ checks in ,” the WES directs the S / RM to dynamically pick and deliver the appropriate product to its designated area for loading . At the same time , an AS / RS provides safer materials handling and reduces redundant , error-prone manual picking processes , thereby decreasing the likelihood of product damage and contamination .
Implementation Considerations
The beauty of an AS / RS is that it can be installed in an existing warehouse or designed specifically for a new facility . However , many companies considering the technology are unsure where to begin . Here are a few considerations to get started .
• Carefully select your vendor . The vendor should possess credentials in your industry vertical ( food , beverage , frozen goods , etc .) and therefore , will better understand your business ’ s unique requirements . As a result , the vendor will be able to recommend , develop and implement a solution that meets your particular needs .
• Purchase high-quality equipment . Lower cost does not mean a better business deal . You ’ ll find that your initial savings will soon be replaced by expensive equipment downtime and repairs .
• Consider the long term . Success is not achieved overnight , so be
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