Next-Gen Wearable devices for Distribution Centre( DC)
Guide | Gourab Kar, Industrial Design Faculty, NID
National Institute of Design Ahmedabad
Sponsor | Honeywell Technology Solutions Lab, Bangalore Business Unit | Honeywell Scanning and Mobility (HSM)
Design Brief
“
Design intervention to leverage Wearable device platform for Honeywell scanning and mobility (HSM).
To enhance productivity and user experience in a Distribution Center by identifying grey areas and satisfying them through innovation.
The Context Distribution Centre | Overview
Not all warehouses are same. Different warehouses require complex material handling work-flows totally different from each other. Each work flow again involves reading variety of symbologies at variety of locations. This new solution should help users in this domain achieve better productivity and better operations with enhanced User Experience.
What it Means to Honeywell ?
There are three different verticals under HSM Business unit like, Warehouse, Healthcare, Transportation and Logistics etc. Under these verticals some of the key needs to be addressed are Multi-modal work-flows, Voice Directed, Eyes Free-Hands Free, Flexible Work-flow. Considering these needs the project scope was to explore potential ideas for Honeywell in Wearable Computing, conceptualize a product and build a business case
(4)
Amazon’s warehouses have more square footage than 700 Madison Square Gardens and could hold more water than 10,000 Olympic Pools. Picking for an order inside that warehouse even t hough seems easy is a major challenge.
Next Generation Wearable Devices for Distribution centre (DC) | HTS, Bangalore
Operational Process Distribution Centre | Overview
Receiving
1 Unloading Counting Identifying Marking Quality Control Registering Goods Assign JBA Number
Putaway
2 Putaway Product category Palletize
Storage
Picking
Packing
3
4
5
Stocking Cycle counting Replenishment Stock rotation Space planning
Searching Navigating Finding Zoning
Confirmation Scan and update inventory Invoicing Staging Loading
Stake Holders Operation type | Directly Involved
Unloader | Receiver | Putaway-Driver | Replenishment Driver | Order filler (Picker) | Loader | Supervision | Facilities and Housekeeping | Inventory Management | Quality Assurance | Asset Protection, Safety | Equipment Maintenance | Operations Research | Information Technology support
Barcodoing Types and Applications
Commonly used types
Retro-reflective barcodes | Location Barcodes | Floor Barcode Labels | Facilities and Housekeeping | Pallet Barcode Labels
Application
Pick-and-Pack Applications | Inventory | Outdoor Scanning | Shipping and Receiving
The order picking function within a distribution center typically account for between 40-60% of total warehouse labor cost. The Cost of Order picking is estimated to be as much as 55% of the total warehouse operation expense
Dolphin Android based Hand Held Terminal
Vocollect used in combination with Ring scanner
HX2 Wrist mounted Mobile computer
Honeywell Ring Scanner
Rugged Design can dramatically reduce breakage and maintenance cost associated with it. This can in turn reduce the downtime as well. Honeywell while ruggedizing their product also follows a design language
Handheld Terminals were bulky but based on the application their build is different
Order Picking Technologies Paper Picking | RF Picking | Visual Picking | Voice Directed Picking | Pick to Light | Horizontal Carousels | Automated or Semi-automated picking
Technology deployment Comparison Matrix | Productivity and Order Picking Technology
Automated / Semi Automated Tech
Very fast Movement category
Horizonatal Carousels
Very fast Movement category
Pick to Ligth
Movement Category
Very Fast and Fast
Very Fast, Fast and Medium movement Category
Voice Directed Picking
Very Fast, Fast and Medium movement Category
Visual Picking
RF Picking
Medium and Slow Category
Medium and Slow Category
Paper Picking
0
100
200
300
400
Velocity in orderlines selected per paid man hour
500
600
700
800
900
1000
1100
1200
Productivity Speed Accuracy Data Capture Capability Flexible and Multifunctional
Hands Free System Cost
Voice Picking
Pick to Light
Visual Logistics
RF Scanning
Best Fit Technology
In applications that demand the constant use of hands, wearable systems give workers the handsfree convenience to handle more tasks, while keeping the technology needed to further improve productivity and accuracy right at their fingertips
Design Considerations Wearable Computers | Order Picking and Distribution Centre
Mounting options Application Flexibility
Wearablilty
Share-ability
Warehouse and Logistics Adaptability
Scanning and Mobility Devices
Modular parts for service and maintenance
Ambidexterity Ergonomics
Multi-modal Interactions Comfort and Fit
Hygiene
User
Designer Usability
Design Process
Research Methodology | LUMA and its methodology
Ethnographic Research Interviewing Fly on the wall observation Contextual Inquiry Walk-a-Mile Immersion
People and Systems Stakeholder mapping Persona Profile Experience Diagramming Concept Mapping
Concept Ideation Thumbnail sketching Creative Matrix Round Robin Alternative Worlds
Participatory Research What’s on your Radar Buy a Feature Build your own Journaling
Patterns & Priorities Affinity Clustering Bull’s-Eye Diagramming Importance/ Difficulty Matrix Visualize-the-vote
Modeling and Prototyping Story Boarding Schematic Diagramming Rough & Ready Prototyping Appearance Models
Evaluative Research Think-Aloud testing Heuristic Review Critique System Usability Survey
Problem Framing Problem Tree Analysis Statement Starters Abstraction Laddering Rose, Thorn, Bud
Design Rationale Concept Poster Video Scenario Cover story Mock-up Quick Reference Guide
Looking
Understanding
Desirability Lenses
Feasibility
Viability
Make
1
2
3
Market Research User Research Trend Study Secondary Research Internal Brain Storming Identifying Design Challenge
Analysis Synthesis Problem selection Developing Project Brief Feasibility road-map
Brainstorming Ideation Conceptualization Prototyping Evaluation Scenario Building
Deliver
Research Plan Phase Overview | Order Picking and Distribution Centre
1
Phase | Pro-Connect Satellite warehouse, Bangalore Phase | Pro-Connect Mother Warehouse ( ADC), Chennai
2
3 4
Phase | Flipkart, WS Retail Warehouse, Bangalore
Phase | Silgro, Cold Storage Unit, Veghel, Netherlands
Pro-connect Warehouse Putaway Operation | Stakeholder and action mapping
Shows PO to Enter
Gate Security Truck Driver + Helper
+ Gives Gate pass
Put-away
Unloads the material
Truck Driver+ Helper
Hands over PO
Signs docket
Assigns dock, hands over palletization report and verified PO
Delivery vehicle comes inside
WMS
WMS
ASN Worker
Verification of PO in ERP and WMS
Sometimes prints and gives JBA
manually check quantity and product ID
Assigns Quality, Checks-in the Received product
Checks PO with ERP and WMS
Check-in Person 1
Palletization report and dock allocation
Distributes PO and palletization report
Stickering/Bar-coding( other value added services like shrink wrapping, bubble wrapping etc.)
Unloading
Check-in RF Handheld device
Builds Pallet and closes check in
Check-in Person 2 Generates GRN Number
Gets transfer level location
Putaway
Receives task after check-in
Builds Pallet and closes check in
Gets Rack Location
Shelves Creation of GRN
Bulk
Finished put away from transfer level to given rack location
Check-in Person 3
WMS
WMS
Racks
Delivers the PO and palletization report along with Stickers if any
VNA Operator
Fork Lift Operator Transfers to the respective Put away transfer level of the rack
Rack Transfer Level
Transfer Level
Builds Pallet and closes check in
Pro-connect warehouse Pickup Operation | Stakeholder and action mapping Sign-in/ Sign-out of the shelf area while entering and leaving the premises
Pickup
Shelf Security
WMS
Order flows to WMS from ERP
Receives pickup order gets dock location for staging
Scans pickup person using metal detector before leaving
Creation of wave(Group of orders)
Uses trolley
Individually Barcodes are scanned
Shelf Pickup Staged Pickups
Picking of Task in HHT
WMS Checks with ERP and Generates Invoice
Racks
Shelves
Bulk
Outbound staging and order consolidation
Barcode Scanner
Physical check with the invoice
Outbound in charge
WMS
Invoice given to the respective courier for docket registration
Docket number updated in WMS and ERP
Casual
Serial number scanning Invoice generation
WMS Person
Extra permits and waybills generated
Time-sheet Generation Loading Vehicle Departure
given back to courier
Courier Person
Third level of check logged in security register
Truck Driver+ Helper Consolidated Goods loaded into truck for dispatch
Outbound security
Flipkart Warehouse ( WS retail ) Order Pickup Operation | Stakeholder and action mapping
WMS
Security
Segregation
Truck Driver
Recieve
Pickup
Checked-in List
Goes for the next putaway
Putaway List Generation
Pickup List for all Pickers are Alligned ready for pickup as per the shift timings
Order Flows from WMS
Picker picks one list at a time and navigates searching for item
WMS
Shelf Location
Order flows to WMS from ERP Creation of wave(Group of orders)
Putaway Person
Picking of Task in HHT
Racks
Shelves
Bulk
Outbound staging and order consolidation
Serial number scanning Invoice generation Time-sheet Generation
Heijunka Board
Pick List Generation
x8
Putaway Assigner Shelf Location
Pickup person goes to pick the next picklist
Pickup Person
If the Shelf Is already Full Putaway person puts the items in a new location and updates manually in the list
Pickup Person
per day
3Km in total WMS
As soon as picking from a single picklist is over picked items are handed over to Assigner
Assigner + Helper
Loading Vehicle Departure
Once Picking is done item is loaded into trolley as per the quantity
Pickup
Based on the Primary research during different phases and secondary research the affinities were collected and clubbed to see if some commonalities and insights can be generated. These insights were kept as the base for all the concept ideation
12.
Affinity Clustering 1. 2.
3.
The device should have minimum weight to avoid fatigue over long period of usage
Need a way to place the device when not in use
5.
HHT used in vehicles are provided with a stool inside the vehicle which is used as a resting place when device not in use
If deep freeze devices are moved out they have to kept out for min of 2 hrs before bringing inside the deep freeze zone
6.
4.
My device can be switchable between Temperature zones in least possible time Chiller zone and Dry Zone are fairly similar in terms of people and equipment
Deep freeze devices should be kept inside that unit itself to avoid condensation inside the device
9.
During picking the palm area has to be kept free for to avoid hindrance
I need clean straps to share between users
The straps are made removable so that same device can be exchanged between different users
10.
14.
I need a Durable Product and long lasting
Battery Status Indication can help in periodic changing and replacement of the battery
Less than 50% speak the same common language in Silgro and Flipkart Distribution centres Most warehouses employ Uneducated employees from different countries
11.
Device has to be fixed in least possible downtime HHT used in vehicles are kept over a stool inside the vehicle when not in use Cost of Repair, Even if its free is considered disruptive and time consuming
18.
Thicker gloves makes ring scanner even more difficult to trigger Trigger is th Mechanical part which gets broken most often and considered for replacement
16.
I need to visually identify my device Ring scanners are always kept in individual numbered cells when charging after shift hours
My Device helps me pick-more and walk less
During operation removing a pistol grip scanner from the mount everytime before scanning is considered as loss of time
Straps has to be washed periodically to remove sweat from different users and are called consumables
7.
Hand Held Terminals are sometimes labelled with numbers or names for identification
Trigger is a Problem
Customers are willing to pay more for a more durable long lasting product
My device has to be natural and Intuitive for a layman across the globe-universal design
For a Huge Warehouse computer route planning is done to minimize the walking distance while picking Ring Scanner can be mounted with either a hand-held terminal or a vehicle mounted device
To compensate for the short wire length sometimes the battery pack is bought closer to the Ring scanner by moving it behind the hand
When Krate is picked from a shelf, probability of hitting against the shelf walls is high in existing configuration
My device should accommodate different mounting options
15.
Ring Scanner is sometimes worn on the upper part of the index finger to increase the Ease of Aiming
Dexterity of my hands should not be hindered
13.
My battery has to be easily replaceable when required
In a Cold Storage area, Its difficult for a picker to change the battery with his gloves on
When picking Fragile items like bottles both the hands should be free enough to handle the items with care
For Bigger hands longer cable Length is required
A Single Battery charge should last minimum atleast for one full 8 Hours shift
Battery Strap Mounted over the shirt full sleeve to avoid skin Irritation
Bluetooth Ring Scanner gets disconnected often when moved between the metal shelves and racks
Device should have the best fit for max users
Straps has to be designed Considering all possible Glove sizes
In voice picking operator confirms their pick with the system before it is complete, so the operator knows that are correct
My Disconnected
Bluetooth Ring Scanner should be within 10 m of the paired mobile terminal
In a Cold Storage area the battery has to be changed very frequently. sometimes a picker here is given two batteries
I need Irritation free straps
Disconnected Bluetooth is paired again by using Reset Button During Order picking the picker has to scan the picked item BT keeps gettingor location bar-code twice for Pick confirmation
8.
My device has to be lite
My device has to confirm the correct part picked
To compensate for the short wire length sometimes the battery pack is bought closer to the Ring scanner by moving it behind the hand
17.
Device should have less wire handling issues Users don’t prefer stretched wires between the battery and the Scanner
19. The picker has to get down from his vehicle every-time he has to pick/ Scan from his assigned parking area
I have to scan fast and pick fast Workers have to constantly check for new task after completion every task to prevent the flow from queuing
Insight Prioritizing
My Bluetooth keeps on getting disconnected
My device has to confirm the correct order picked
Device has to be fixed and serviced in least possible down time
Device should be swithable in least possible time
Need a way to place my device, when not in use
I need irritation free Straps
My battery has to be Replaceable when required My device should support Multiple modes of Data acquisition
Need a clean strap to share between the users
Dexterity of my hands Should not be hindered
Device has to help Walk less and pick more Trigger is a problem
I need to visually Identify my device
My device should accommodate flexible mounting options I have to scan fast and pick fast
Tertiary
Insights
I need a durable and Long lasting product
Universal Design: Device should be Natural and unobtrusive for everyone
Device should have Less issues due to wire
Secondary
My device has to Be lightweight
Primary
Posture Study Order Picking| Scenario Considerations During the primary phase of the research, while shadowing different operators in the warehouse their general posture while operating and scanning was studied and documented. These gave valuable insights before conceptualization
While using trolleys or baskets for carrying bigger boxes
Palletization or docking of picked order
Searching objects of varying Geometries in a shelf
While lifting multiple boxes together
While using material handeling equipments while picking
While changing grip For conveyor sorting and docket updation
While bending and lifting a box
Concept #01 The Core | Chest Mounted
Description This concept, CORE is based on the fact that to reduce fatigue keeping the weight of the wearable device as close as possible. Once mounted on the chest the wearable also strategically gets the position of aiming at most of the boxes being carried by both the hands
Scanning unit detached
Mounting gear
Chest mounted computer Usage Scenario Hand-held Scanning device
Belt strap locking
Not all the scan targets are accessible from the chest. So in case the user decides to reach little farther he can always detach the scanning unit from mobile computer
Info Screen
Key information related to the order to be picked can be shown
Concept #02 The Ring | Mechanically Triggered
Trigger
Axis of the clip hinge
Trigger
Clip to lock and mount Scan-engine Washable silicone insert ( Consumable)
Scan-engine
Adjustable clip jaw
Bar-code symbol
Finger Glove
Finger glove with single finger cap and scan engine
Easy wash consumable
Usability while scanning
Scan head Removing Washable silicone insert ( Consumable)
Usage Scenario Finger clip scanner side view
Trigger to Scan
Adjustable strap Finger cup
Concept #03 The Ring | Gesture Triggered
2. Description While a Ring can be non intrusive and provide an eyes-free and handsfree operation, Triggering the scanner is always still not intuitive. This concept explores gestures to trigger the OCR detection
Usage Scenario 1
1.
Point Gesture Ring Scanner (Orientation#1)
Battery compartment Scanning camera
Scan Direction
Point to the bar-code to be scanned
1.
Wave Gesture Tap two fingers and wave over the barcode to scan
Ring Scanner (Orientation#2)
Ring #2 Notch for finger movement
Disadvantages Gesture recognition at current stage might increase the total cost of the equipment ( this reduces the ROI calculation for warehouses)
Usage Scenario 2 Wire to mobile computer
2.
Concept #04 The Loop | Voice and Scanner based
Locked State Detached state
There are totally three components for the device when its in detached state
Pull to use
3.
Pendant Connect
Description The Bluetooth audio piece is used for voice based task management and Finger shell is used for scanning barcodes of product picked instead of voice confirmation
Finger shell and Bluetooth earphone locked state
Advantages More emphasis is given to Voice with a hybrid integration to scan.
Product is handy, Eyes-free while operation.
Pendant like wearable
Disadvantages Too many loose parts,fear of losing. Not Suitable for intense scanning application but might be relevant to many retail applications
1. Bluetooth Audio Piece
2.
Finger Shell Scanner Usability
Negative of the Shell can be used to house the bluetooth audio piece
Scan-head Shell Finger while in use
Concept #05 Modulo | Belt strap with modular scan heads
Inside Another extension of the idea is to Warehouse Naviga- provide peripheral LED based navitions gation for pickers to guide them to Module #1
Modular scan heads with retractable springs
take the shortest possible picking distance while they are doing multiple picks from multiple locations. This can save time and will be a serious productivity enabler
1.
Peripheral LED signalling
Top View of the device
2.
1.
Module #2
Modular scan head, with artificial ip
Charging blocks
Usage scenario: With retractable scan head
Individual docks is also modular based.
Usage scenario: With retractable scan head
2.
Array Charging
Using the same modular locking. Instead of plugging a scanner head the device can be plugged into similar docking stations for charging.
Concept #06 Glass | Safety Glass Integrated
Detached scanned Description Most warehouse operations might require additional safety glasses to be used. This concept explores the possibility of using a scan engine mounted to the safety glass to scan
Disadvantage Per day the person might have to scan more than 1000 Production. Every-time looking for a product to scan might increase his fatigue associated to his neck
seamlessly just by looking
2.
1.
Safety Glass mounted
3.
Concept #07 *Digitus X | Glove Integrated
Description Most of the current hand mounted wearables are in the vertical plane for a palm. While moving the hand inside a carousel or shelf during pick operation the chances of device hitting and causing hindrance is high. But in this concept the scan engine is kept on the horizontal plane. This is more similar to having an extra sixth digit on the same plane
Secondary display
Scan Engine Hybrid With voice picking
Trigger
Trigger to scan Scanning with least
possible wrist rotation
Scanning with least possible wrist rotation
Strap
Usage scenarios Scan Engine
Elastic
Direction of scan
Glove Concept #1
Out of all the various concepts generated, Digitus-X , The glove integrated scanner created good amount of attention when was critically reviewed among different peer groups of varied technical expertise. For other concepts advantages and disadvantages were discussed and they were also analyzed for future scope. But Considering lot of parameters like immediate market feasibility, innovation, inventiveness , non obviousness etc. Digitus X concept was taken for detailing further refinement.
Concept 7
Concept 6
Concept 5
Concept 4
Concept 3
Concept 2
Ranking and Selection Matrix
Concept 1
Concept Shortlisting
Feasibility Non Obviousness Fatigue while opertion Flexible and Multifunctional Hands Free Ease of Use
02
05
03
06
04
07
01
Hand Ergonomics Observations | through Interpretations and anthropometry Hand Poses while Different possible poses of hand order picking while the person is order picking is considered to design the glove width and dexterity required. This study helped in fixing up the wearable device configuration with least possible intrusion, scanning with least possible wrist rotation.
Hand length, 184 mm Palm length, 106 mm Hand Breadth with thumb, 102 mm Hand breadth without thumb, 84 mm Hand depth, 26 mm Hand depth at thumb, 49 mm
75th Percentile for Industrial Workers
Individual Finger move-
ment horizontally
8.4 cm Anthropometry Maximum breadth across the palm at the distal end of the index and little finger
Wrist bending while picker rests his hand for support over any surface Horizontal plane for the palm seems to have less intrusion than vertical planes.
8.4 cm
While lifting any geometric boxes during picking
Palm Width without the thumb for 75th percentile
Centre palm fold
Default Neutral position of any hand
Concept Detailing
Digitus-X
Digitus X Product Architecture | Major Components
Cotton weave Glove
3.
Modular Battery Strap
3.
1. 2.
2.
Scan Module
1.
Fit and Comfort
Front Velcrow strap (to change strap fitl)
Fit and The inner glove is made Comfort of cotton weave. This
can be custom for every person using the device and also can be washed periodically
3.
Straps
1. 4.
1. 2.
For increasing fit
For removing battery
Battery Status button (Press to check battery level)
2. 3, 4 for removing the device and adjusting the device over the cotton weave glvoe
Battery knowing the battery Status charge status is import-
ant. The battery status button indicates the level of charge whenever pressed. The Status could be 25%, 50%, 75%, 100%.
Velcro strap adjustment (to change strap fit)
(Elastic battery wire)
Component Details
Before Scanning (while Capturing)
Mechanical Trigger Trigger Activation Glove mount plate
1.
Breathable Leather
PCB mounting board PCB with scan engine
Ruggedized Shell
After Scanning (Scan Confirmation)
Cotton mesh ( consumable)
2. RJ 45 Ethernet socket
Battery units
the index finger and thumb. The conformation fo a successful scan is given by the LED glow like shown towards the right.
Component An Exploded view of all details components and modules associated with Digitus-X
Trigger and Scan Activated while squeezConformation ing the button between
Battery wire
Internal Details
Flex Flexible ribs are provided Reinforcement internally as reinforcements so that the glove can remain beter functional and fit the hand
PCB PCB Size approximation Ratio 2:1, If Diameter of the coin=25mm
Battery Weight Battery is split into numDistribution ber of modular units to evenly distribute weight and to make it flexible
Internal PCB and scan engine
Š 2014 Arjun Raj Kumar S | National Institute of Design, PDPG 2011