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Best Practices in A Cold Storage Warehouse

A Brief:

Cold storage is the storage of any temperature controlled substance that prevents the substance from decaying or not adhering to the basic regulations that apply to that item.

Cold storage warehouse management is a highly specialized skill which requires comprehensive knowledge of the industry, the ability to monitor processes closely occurring both inside and outside the facility and constantly staying up to date on new and evolving state of the art technological solutions available.

Effective management of a cold storage warehouse is no small joke, however it requires close attention to detail and management techniques to ensure optimum productivity is maintained, despite the harsh & freezing conditions. As demand for perishable products grows across the world, efficient and effective cold chain management requires strong partnerships and quick turnaround time.

Distribution centers across the regions share many of the same challenges, whether it be space optimization, picking methods or the integration of automated systems. However, managers of cold storage facilities find themselves in the peculiar situation of not only being responsible for maintaining the quality and safety of their sensitive stock, but also the safety and well-being of their workers under these typical environmental circumstances.

Refrigerated and frozen foods account for the majority of products stored in cold storage warehouses. Cold storage is also vital for other industries as well such as pharmaceuticals, petro-chemicals and even high-tech electronics.

Following are some challenges impacting cold storage warehouse management:

  1. Food protection  

Regulating and maintaining the right temperature and humidity to maintain and extend the life of your products can be challenging as well as risky, as different products require different temperatures to be sustained. Traditional temperature monitoring systems depend solely on the experience of the operator who must be on-site to adjust and manage the whole system.

  2. Maintaining product’s lifecycle

Correctly maintaining the temperature of perishable products is necessary to preserve its quality and safety from the start point of production through the supply chain to the consumer. Failing to maintain proper shipment leads to textual degradation, discoloring, damaging and infective growth of food products.

  3. Labeling product and racks

Barcode labels create the essential link between physical products and the computer systems that monitor receiving, storage, retrieval and shipments. Appropriate freeze-grade rack labels serve as a critical factor in the entire traceability system. Freezer-grade rack labels develop a strong permanent bond on common rack surfaces, and can be applied in environments as low as -20°F.

  4. Product traceability

In the case of temperature excursions, finding out and determining the affected product is only possible with accurate location information. Products like fresh produce require additional control over factors such as carbon dioxide and humidity. Very Specific and accurate documentation is mandatory.

  5. Fulfillment and courier shipments

The entire cold chain process should be about minimizing the time it takes to move a product through the system. Chances of vulnerabilities are higher if there are delays in handing products off from one facility to another.

  • The average shipment—both inbound from supplier to distribution center, and outbound to customers—is made up of less-than-truckload amounts of food products.
  • All products must be loaded correctly to prevent any cross-contamination with the raw product and damage with the heavier items placed at the bottom.

Perishable foods, particularly seafood, pre-cut produce and ready-to-eat products, can become unsafe if not kept at the appropriate temperatures.

Best practices in a cold storage always help you in better management of the storage; here are a few practices that will help you in better management

  1. Conquering the alternating temperature ranges

In cold storages, energy savings is a recurring concern. It’s a fact that it is far more expensive to cool the air than to heat it. Moreover, different products might have varied temperature requirements.

For example, vegetables need a temperature of approximately 12° C , meat needs to be stored at around -2° C, dairy products at 1°C and ice cream needs a temperature of –23°C.

So, this can be quite a challenge for third-party logistics (3 PL) who may have clients all across the year with variable storage requirements. Moreover, in a cold storage environment, re-configuring the space is not as easy as it would have been in conventional warehouses because one needs to take care of the cold temperatures.

All warehouses that need multiple temperature zones or where there are a mix of products that are stored change with the season, usage of pre-fabricated wall system may look feasible and flexible. But, the refrigerated air can be expensive, so the cost savings are realized only after you make one change to the wall or a room.

  2. Opt for automation to avail savings

The cost of workforce, space and energy is increasing at an exponential rate. Because of this the operators of cold storage warehouses are moving on to automation to be cost effective. The increase in the operational costs can be reduced through various automated solutions. In some cases, automation can also reduce the energy requirements by as much as 80%, space requirements by as much as 50% and finally the labor requirements by about 70%. Such savings can be realized in several ways.

  3. Control heat loss

It will be wise to keep the area as small as possible for food since food is one of those areas where air can escape easily. High-density storage tends to create a smaller area to cool. It also develops an environment that can minimize heat loss. Storing stuffs closely creates a smaller area to cool and an environment that minimizes heat loss. Automated storage also minimizes the amount of warmer…

Warehousing in 3PL

Third-party logistics (3PL) providers are establishments that provide solutions to help various businesses manage and execute the logistics of warehousing in a better manner.  3PL service providers can boost warehouses’ success rate and simplify their customers supply chain. They also help in bringing effectiveness in order fulfillment and shipping transport. In a nut shell a 3PL (third-party logistics) provider offers outsourced logistics services. In essence, 3PL companies monitor and manage warehousing operations, the transportation of goods and order fulfillment.

WMS Technology in 3PL

Implementing a comprehensive warehouse management system enables a 3PL company with organized data on warehouse stock, and an easy way to keep track of goods belonging to multiple clients. WMS technology can improve slotting and picking patterns and increase communication between transportation management and warehouse management systems. Advance WMS systems can also communicate with labor management software, which helps companies optimize their workforce. 3PL operators today also are extending services beyond basic warehousing & provide consulting and advise the retailer or manufacturer on the best course of action.

Improved Warehousing Experience

Warehousing is the crucial link in the entire supply chain and leads to perfect order fulfillment if designed and managed professionally. Several tasks such as receiving, storage, cross docking & shipping activities are performed under a warehouse. When operating a warehouse, businesses always come across questions about storage structure, inventory management, resource planning and so on.

Appropriate solutions to these concern areas make any warehousing operation efficient, which in-turn leads to organized processes and subsequently enhance productivity. Seasoned 3PL service providers know their warehousing network in and out and are fully capable of fulfilling warehousing needs for any kind of product and type of operation. Warehouses managed by 3PL providers are the perfect storage and distribution choice irrespective of whether your products need racking or surface storage, palletized or non-palletized, etc.

A Perfectly Designed Warehouse

In the entire supply chain cycle financial investments in warehousing is one of the largest by any business. Unaligned warehouses for the strategy planned, leads to inefficient order fulfillment rate. Corporates should ideally understand that alignment with 3PL providers will bring down their warehousing cost and they can use a perfectly built warehouse with all the latest facilities to store their inventories at a cost effective monthly rental model.

Well Defined Storage Process

3PL providers provide customized services from heavy shelving to light racking, pallet storage to piece storage and using best storage method to store the product. Every product is unique and needs to be stored properly for efficient picking and order fulfillment. This is the basic rule of warehousing to store heavy, light, fragile, perishable and temperature controlled cargo separately along with utilization of maximum warehouse space. Storage methods should be in a way to make your warehouse operations most efficient and save storage cost, picking time and reduce the possibility of wrong shipping.

Process Importance

Warehouse is considered as the storage and distribution hub of any business. Right from setting up to running daily operations, warehousing brings multiple challenges to the business & should be error free. Along with challenges, it is absolutely not feasible for individual businesses to own and operate warehouses on their own.

Process adherence for operating a warehouse makes it more efficient. Inbound and outbound processes should be well defined and implemented. A process-less operation always lead to unfulfilled orders, missed TAT, mismatched inventory levels leading to less warehouse efficiency. Outsourcing warehouse operations to an expert 3PL partner resolves all your operational challenges. 3PL service providers always make sure they follow a standard operation procedure considering the customers supply chain strategies and ensure required throughput is achieved consistently.

Embrace 3PL

It is a fact that partnering with 3PL service providers can always fuel warehouses’ success factors and bring drastic simplification in your entire supply chain. But then there are always some flip side to the same and problems may arise.

An important disadvantage is that direct control over the processes in warehouse management cannot be held. This lack of control can sometimes lead to customers having to settle for little to no clue on the way that a warehouse is run.

But with technology based tools that are available today, it’s easier for 3PL companies to provide end to end visibility to shippers that use their services. Hence it is very key that 3PL management companies implement modern technology which shall then surely lead to a rise in their adoption.

IT enablement – By 3PL, for 3PL

In the recent studies it’s established that an estimated around 86 percent of Fortune 500 companies and 96 percent of the Fortune 100 use 3PL services.

Witnessing a paramount growth in the usage of 3PL warehouse and inventory management software, 3PL companies are slowly starting to embrace the best IT solutions & some are even developing their own solutions. One substantial help to this is that 3PL companies are well aware what’s the key to be a leader in the market.

3PL companies are gearing up and standing up to the need of the hour and developing software which offers many other key benefits. This definitely brings in advantage such as reduction of downtime when integrating the new solutions. With in-built software developed specifically for the use of 3PL companies what we can expect is drastic reduction in downtime during the implementation of new software.

Conclusion: 3PL operators shall continue to establish their presence for a long time and will provide a series of benefits for customers that integrate their services. An effective & optimum usage of time and resources coupled with efficiency and customer delight are vital in ensuring a healthy supply chain management. With the rise in trend of shipping and warehousing demands there is no doubt on the significance & growth for 3PL centric warehousing, inventory and transportation management solutions. Fur business houses it’s time to take a wise decision for adopting a 3PL focused WMS technology solution with the current state of maturity attained surrounding the 3PL business domain.

Industry 4.0 for Supply Chain – The role of AI (Part 3)

Industry 4.0 for Supply Chain – The role of AI (Part 3)
Industry 4.0 for Supply Chain – The role of AI (Part 3)

This is part 3 of a 3-part blog, addressing the 3 questions below.

Part 1 – What is Industry 4.0?

Part 2 – Where does Supply Chain figure in Industry 4.0?

Part 3 – What is the role of AI in Supply Chain for Industry 4.0?

You can find Part 1 here.

You can find Part 2 here.

Artificial Intelligence in Industry 4.0, Digital Supply Networks

In the first two parts of this article we covered Industry 4.0 basics and looked at Digital Supply Networks. We understood how automation and the internet of things come together to create a connected world that personifies Industry 4.0. We saw how systems and applications could integrate and coalesce into this massive, constantly evolving and adapting organism called a Digital Supply Network. Automation, connections and integration provide the physical structure of the digital supply network. Artificial Intelligence infuses life into this organism and makes it functional.

AI Steps Up

Digital Supply Networks derive their true benefit by being responsive, adaptive and real time. Without any of these characteristics, they would not be able to differentiate from traditional supply chains. These characteristics require that the supply chain be able to handle whatever is thrown at it, accommodate umpteen scenarios, learn new paths, optimize for cost, utilization and other factors, all of this in near real time and round the clock.

The supply chain needs quick, intelligent, optimal decisions all the time. Artificial Intelligence has come of age and makes this possible. Distilled human intelligence in the form of algorithms, machine learning, neural networks that discern patterns, insights from analytics and statistical routines that use them with “current” information all facilitate real time decision making by systems. Rule and role based human oversight bring in the ability to tap expert intelligence for critical decisions and approvals.

Industry 4.0 for Supply Chain – The role of AI (Part 3)
Industry 4.0 for Supply Chain – The role of AI (Part 3)

AI takes over tasks that humans perform and provides consistent quality output, in much lesser time. Tremendous improvements in computational power and toolsets have given plenty of teeth to AI. The AI systems in Digital Supply Networks take care of planning and scheduling, allocation of resources, process customization and optimization.

Real world applications

Let us look at some specific applications of AI in supply chain.

  • Forecasting of demand based on historical patterns and current factors can be effectively done to in turn aid resource planning, production planning and procurement. Optimal inventory levels can be achieved to ensure SLAs while not locking up capital, based on analytics and forecasts.
  • Scheduling of operations in factory and warehouse environments can be done based on the order book. AI can optimize these schedules to improve utilization, reduce costs, evenly distribute work and more.
  • Turnaround time for picking and put-away operations in the warehouse can be reduced using intelligent suggestions for locations to store material or pick them from. Machine learning ensures that the system learns and improves continuously.
  • Dock and truck scheduling for loading and unloading in busy warehouses can be done by systems that can factor in constraints such as arrival and departure time restrictions, lunch breaks, breathers between trucks, skills and equipment needed for trucks such as forklifts, size of team needed for the order, special needs such as cold docks, extra-long trucks and so forth.
  • Loading sequence and pattern for storage bins, trucks to maximize space utilization with bin packing techniques. In case of trucks the loading sequence also can factor sequence of delivery to ensure ease of access.
  • Route planning for delivery in case of milk runs, as well as for on demand orders can be created to reduce travel time, reduce fuel costs, optimize number of trucks needed. Information pertaining to traffic, preferred delivery slots can be used in planning while ad hoc orders and express orders can be dynamically factored in to re-plan with minimal disruption.
  • Goods to picker solutions with automated robots require intelligent traffic management within the warehouse to reduce power costs, time needed and avoid log jams, while efficiently scaling up to meet demand.

Artificial Intelligence’s true power comes to the fore when it goes beyond automation of mundane human decisions, to working with factors that do not model easily, learning from data, dealing with numerous complex factors, large scale, quick turn-around needs.

As we saw from the potential applications listed above the intelligence is distributed across sub-systems. The federation of these intelligent subsystems creates a powerful collective intelligence where each subsystem provides stimuli/inputs to other subsystems.

This brings us to a conclusion of the 3 part-article. Embracing Industry 4.0 entails big changes to processes, organization ethos, skillsets and infrastructure. It opens up revolutionary possibilities and readies organizations for a new age economy. Take steps today to stay ahead of the curve and participate in creating and shaping the new age economy. Coming soon! How to get started with your Industry 4.0 journey.

Industry 4.0 for Supply Chain – The role of AI (Part 2)

Industry 4.0 for Supply Chain – The role of AI (Part 2)

This is part 2 of a 3-part blog, addressing the 3 questions below.

Part 1 – What is Industry 4.0?

Part 2 – Where does Supply Chain figure in Industry 4.0?

Part 3 – What is the role of AI in Supply Chain for Industry 4.0?

You can find Part 1 here.

How does Industry 4.0 influence Supply Chains?

Industry 4.0 and the Internet of Everything (another name for IoT), bring a connected world into play. The benefits to be reaped are possible precisely because they are all connected. To elaborate this let us look at an example.

The car manufacturer Toyota has established just-in-time manufacturing practices. The inventory levels of car parts that they hold have shrunk to accommodate these practices. The assembly line gets parts from Toyota plants and from their ecosystem of suppliers. Toyota conveys their need for inventory at a detailed level to their suppliers who deliver just in time. This brings down costs dramatically for Toyota. In a connected world any change in the production plan at Toyota will be automatically notified to the supplier, who in turn can ramp up or ramp down their production. Such plan changes can be in turn notified to their suppliers who can act on this information. The flow of information can traverse the entire supply chain and can result in business decisions being made in the best interest of each of the parties involved.

Digital Supply Networks

Digital Supply Networks are the supply chain networks of the future. They are characterized by being connected / digital. They are real time networks that offer online access to services, as well as visibility in the execution. They can offer scheduled as well as on demand services and can respond to demand stimuli to fine tune the supply. Let us see what all that jargon translates to with an example.

An interior designer is furnishing an office space and places an order on an ecommerce portal for specialized lighting equipment. The order includes customization such as color and style of casing and printing of the company logo on the casing. The customer has chosen to pay a premium for quick delivery. The placement of the order triggers a chain of events that flow through the digital supply chain. The factory gets a “priority” order that is scheduled for production. The required quantity of casing for that order is not available in stock, automatically creating a shortage alert. The system places an “expedited delivery” order to cover the shortage and also ensure recommended minimum inventory level for that type of casing. A forecasting model ingests data for this order, as well as the stock shortage to fine tune the minimum inventory level for the casing.

The casing supplier places an “on demand” order on his transportation partner to deliver the casings from ready inventory to their customer. The transportation partner is an aggregator who allocates a truck based on proximity, vehicle type and other business factors. The casing supplier also starts a production run to replenish his ready inventory. His production system places an order for raw material on their supplier. A smart contract raises an invoice on the factory as per payment terms for “expedited delivery”. The contract settlement triggers are sent to finance departments.

The factory which is now producing the lighting equipment also schedules a delivery of the finished product to the e-commerce portal’s designated cross dock. Their fleet provider who has a set of trucks works out an optimal fleet plan for the day based on orders on hand. The factory is informed of an ETA for the truck to pick up the goods. Alternately the factory can specify an expected time that the fleet provider can factor.

When the products are ready, the orders are delivered by the ecommerce company to the customer within the guaranteed time. The number of business that come into play to make this happen are numerous and they constitute the digital supply network. These businesses are connected and can send each other real time updates as well as service requests or orders. The businesses themselves are dynamic and align/realign the execution to incoming orders.

Digital Supply Networks are built using ecosystems and providers who can be tapped on need basis. These businesses are able to talk to each other digitally, thanks to APIs that allow integration. Services can be ordered, status can be tracked, alerts are pushed and the provider is truly online and real time. Some exciting technology such as smart contracts and blockchain are ushering in the potential to work with even new providers in a trusted manner.

Each link the supply chain has to learn how to be real-time and dynamic in their business to leverage an ecosystem that can save costs as well as increase service levels dramatically. Retail shops, distribution warehouses, ecommerce cross docks, manufacturing units, fleet providers, aggregators, truck owners, finance departments, ports, banks and financial institutions, trusted platforms will all be part of this digital supply chain that is a living breathing organism which will respond to customer demand. Exciting times ahead.

In the next part we will look at how Artificial Intelligence plays a role in digital supply networks.

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