Paperless warehouse systems became a buzzword in the cold storage industry about five years ago. By eliminating paper pick lists, they are designed to cut operational costs. However, many warehouses still don't have them, according to the International Association of Refrigerated Warehouses.
One of the most recent paperless technologies is speech-recognition. Last year, it came to the attention of P&O Cold Logistics in Henderson, Nevada, after Ross Smith, company vice-president and chairman of the IARW's South Pacific chapter, heard a technology presentation.
“I thought that voice-recognition management could increase order selection productivity and accuracy,” Smith says. “So we examined the SyVox SpeechNet Logistics system and installed it early this year.”
One of P&O's largest facilities, the Henderson warehouse provides more than 11 million cubic feet of refrigerated storage. It handles everything from ice cream to packaged meat. Temperature zones range from 38° F to -20° F. The three largest customers are either major food manufacturers or food retailers.
“Twenty warehouse workers use the SyVox units,” says P&O's Senior Information Technology Manager, Jason Osborne. “In a cold room environment where employees have to wear gloves, it's awkward trying to handle paper and pencil while picking product. Our workers previously used computer-generated labels and pick sheets. Now their hands are free. They like the new system much better.”
Lightweight Data Units
Workers wear a lightweight belt to support the Speech Data Terminal 7200, a speech recognition unit, and a headset.
The Speech Data Terminal provides 64 megabytes of RAM and over 3 gigabytes of storage for the Windows 98 operating system, speech software application, and data. Scalable architecture allows additional memory to be added as needed. The units work off rechargeable batteries that provide four to six hours operation at eight transactions per minute. Two batteries provide enough power for a full work shift.
Audio hardware enables high-performance speech recognition and synthesis, says Tiffany Dawe of SyVox. The speaker-independent system uses advanced technology to recognize any voice, not just a single voice. Thus, workers require minimal training.
“We pinpointed many reasons for selecting SyVox, including the short time to implement, ease of deployment, and elimination of software development,” says William Duffy, P&O president. “We were also impressed with the ability of SyVox to track warehouse productivity in real-time.”
“SpeechNet offers time-saving benefits, allowing workers to record activities in real time, shortening data entry lag time, and heightening accuracy,” Dawe says.
SpeechNet and WMS
SpeechNet communicates with other warehouse management systems, including the in-house-designed system at P&O's Henderson facility. “SpeechNet has specific picking modules that allow workers to receive instructions and verify completion of tasks verbally,” Dawe says. “Our standard, yet configurable software allows us to adapt our system to the business rules of the warehouse.”
The SpeechNet Control Unit is an industrial computer that houses the SpeechNet Engine, speech processor, connectivity manager, administration console, applications plug-ins, and SyVox's Interactive Speech Interface Specification. It relays data from the warehouse management system via a wireless network to individual speech data terminals where it is synthesized into speech. Workers hear instructions through the headsets. For example, “Go to aisle 3, bin 10, pick 14.” When workers complete a task, they speak into the microphone, “got it,” and receive their next instructions.
In Henderson, P&O uses SpeechNet only for case picking. “We aren't using it for receiving, loading, or replenishing,” Osborne says. “We only use it for case selection in load consolidation. Manufacturers ship pallet loads and we store them. Later we receive orders to pick by the case for outbound direct-store delivery.”
Fast-Growing Chain
When opened in 1989, the Henderson warehouse was 64,000 sq ft. It doubled in size to 128,000 sq ft in 1995, added another 48,000 sq ft in 1997, and in 2000 opened a separate 162,000-sq-ft building.
One of the fastest growing warehouse chains, P&O operates 17 facilities nationwide. The Henderson facility does not run trucks. But nationwide, the chain operates fleets in Los Angeles, Boston, and San Antonio. “We are a case-pick operation,” Smith says. “We rely on a core of three or four major refrigerated carriers. Our customers generally take care of transportation.”
The facility runs at near capacity all year. “We offer a special service for carriers who haul for one of our customers, an ice cream manufacturer,” he adds. “The manufacturer requires that trailers be precooled to -20° F. This isn't always easy to do in Henderson, one of the hottest places in the US. It's not uncommon for the temperature to rise to 115° F in summer. In the past, it literally has taken hours to pull down trailer temperature.”
P&O now offers a solution. For a fee, carriers can back trailers to two specially equipped door positions with refrigeration from the warehouse's ammonia refrigeration system. Trailers are backed to company-designed, 10-ft-sq boxes with bumpers to provide a good seal. The refrigeration system pulls down box temperatures to below zero within 40 minutes, even after trailers have been sitting out in the Nevada sun. P&O President Duffy developed the special units.
