Next Gen Wearable devices for Distribution Center (DC)

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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



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