Home
  Users
  MH Glossary
  Material Handling Info
  How to Get Started
  Daifuku America
Material Handling Information - Too Many Data Entry Points
   
Errors
Too Many Data Entry Points

Incoming boxes of beef are automatically scanned into Excel's inventory control system, eliminating manual data entry and making products immediately available for order fulfillment.

With more than 60,000 SKUs in stock, Northwest Airlines depends on RF-terminals and Warehouse Management Software (WMS) to streamline data entry and ensure fast, accurate order picking.
Problem
  • Manual data entry at any point in the process duplicates steps, causes delays, and creates opportunities for errors.
  • Conventional picking uses printed pick lists, handwritten operator pick confirmation, and final data entry from the annotated pick list.
    • Lost pick lists cause data entry errors.
    • Missing items on an order requires reprint of pick list or label.
    • Wasted time between order receipt, order assignment, picking, and confirmation of order.
    • Manual process for expediting urgent orders.
    • Workers not given direction for next pick assignment.
    • Peak order times overwhelm manual data entry process.
    • Any inventory shortages take time to update and require manual expediting.
    • Multiple pick lists for the same order require additional data entry steps when the order is consolidated.
  • Cycle counting updates require double entries, creating delays and opportunities for data entry errors.
  • Data entry delays can create subsequent picking problems.
  • Quality Assurance sampling adds an administrative step to incoming products, delaying the release of inventory for picking or put away.
  • Incoming inventory that must be inspected before putaway takes up floor space in receiving.
Receiving data entry points
  • Expected receipts (purchase orders)
  • Ship manifest verification
  • Receipt into inventory
  • Reconcile against expected receipts
  • Assign inventory location
  • Quality assurance check of selected items, vendors, or carriers (done after or during receipt into inventory)
Order-fulfillment data entry points
  • Pick list
  • Pick list annotation
  • Pick confirmation
    • Inventory update
    • Order status update
  • Inventory cycle count update
  • Consolidation confirmation
  • Packing list
  • Value-added label
  • Value-added label confirmation
  • Box/pallet label
  • Box contents confirmation for order accuracy
  • Ship container confirmation
  • Carrier assignment
  • Ship manifest
  • Bill of lading
Solution
  • Automate or eliminate as many data entry points as possible using Warehouse Management Software (WMS) and RF terminals to:
    • Scan bar codes for location, load/pallet ID, and SKU instead of entering data manually.
    • Transmit data between accounting systems and WMS to avoid printed lists (i.e., expected receipt, ASN, pick list).
    • Transmit inventory data in real-time at each point in the process.
    • Direct order picking to avoid delays and duplicate entries.
    • Confirm picks and update inventory data in real-time.
    • Direct consolidation and ship confirmation to avoid delays and confirm order integrity.
    • Dynamically reassign pick locations in case of shortages.
    • Cross-dock from receiving to shipping.
    • Allocate picking resources based on expected demand.
    • Plan pick assignments by shipment.
    • Dynamically update load weight and generate shipping documents (i.e., packing list, shipping label, ship manifest, bill of lading).
    • Maintain history of orders, products, and shipments, including contents, date and time shipped.
Case Study Applications
Guest Survey