DC Velocity - November 2009

the location by reading off the rack’s check digit number.

About 90 percent of bin locations contain multiple lots, which means the voice system must be very specific in the instructions it provides regarding the lots and quantities to be picked. The worker confirms the pick by reading back the last four digits of the lot number and the quantity selected before depositing the items into the tote. The voice system then repeats the process for any other items needed from that zone. Once all the picks in a zone have been completed, the tote is passed to the next zone until the order is complete or the tote is full.

For the remaining 10 percent of bin locations—those that contain a single lot—pickers follow a slightly curtailed procedure. In those cases, the software automatically skips the request for lot confirmation, which helps speed up the picking process.

The voice system is designed with flexibility in mind. For instance, if a worker receives instructions to select items from a particular lot but finds the lot is no longer available within the zone, he or she can pick from another lot of the same SKU, informing the voice system of the change so it can update the pedigree record.

Sounds good

Since converting over to the new software and voice-directed system, the Livonia DC has been able to ship orders on time and handle higher volumes, Swoffer reports. “We have more than kept pace,” he says. “We actually do more lines today and have increased our volume, while adding the additional steps for the pedigree requirements.” The facility now averages about 12,000 lines picked a day, with a peak of 18,000.

Order accuracy is up as well. Picking accuracy this year has run about 99.93 percent, up slightly from 2008 numbers. But with the strict pedigree requirements, 99.93 percent isn’t good enough—the company will accept nothing less than 100 percent. So Harvard Drug has set up an additional validation process to ensure that all errors are corrected before orders leave the building.

As for what’s ahead, the company hopes to roll out the voice system (which is currently used only for picking) to the putaway and cycle counting functions at the Livonia DC. It is also looking to implement voice technology next year at its facility in Indianapolis, a smaller center

that houses a case picking operation.

“I really do not think we could have gotten through all of our processes with the speed we needed without voice,” says Swoffer. “It gives us a clear competitive edge, and that is why we want to expand it to our Indianapolis DC.”

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