Description

Technically, this is the first fully digital fork camera in series production, with full HD resolution, broadband automotive Ethernet data transmission and software for transferring the results to any WMS. For the Jungheinrich WMS, the product is equipped with additional intelligence, which, by means of coloured overlays in the camera image, makes it possible to recognise whether the correct or incorrect barcode is located in front of the tine as it passes by. In addition, an acknowledgement button is mounted near the steering wheel, so there is no need to handle the hand scanner.

The product is designed to make stacking and retrieval fast and error-free:

1. Hands remain on the truck controls and do not switch between the truck and handheld scanner.
2. On-site scanning at the storage compartment and/or the goods avoids scanning incorrect barcodes from a list at the rack foot, which ensures that the WMS always receives the correct data and avoids incorrect deliveries.
3. The high-resolution, digitally optimised image even allows labels to be read at great heights, avoiding unnecessary unstacking of incorrect goods.

Innovations

Currently, fork cameras and handheld scanners are used. The fork cameras partly use analogue technology and provide much less information. With handheld scanners, codes have to be scanned from barcode lists and posted to the “correct” order in a very error-prone process. Using the latest technologies, the addedVIEW fork camera with scanning integrates both functions. A fully digital camera with full HD resolution and integrated image processing software for barcode recognition distinguishes between the correct and incorrect barcodes. The connected middleware for transferring the information to any WMS or, in the case of the Jungheinrich WMS, with extended communication and image processing functions, indicates whether the correct storage compartment has been reached by means of coloured overlays (red/green) in the camera image, even as the forks pass by.

Scanning with the fork camera means that the location of the goods movement and the location of the scan coincide. In this way, previously undetected storage/retrieval errors can be drastically reduced. For example: incorrect storage, but scanning the “correct” barcode expected by the WMS. Or retrieving the wrong goods, but scanning the “correct” barcode expected by the WMS. The complete chain of camera, data transmission, image processing, forwarding to the WMS (and, in the case of Jungheinrich, even the WMS itself) were newly developed or expanded – to form an integrated series solution that is unique on the market.

Market relevance

The integrated series solution presented is unique on the market, because the addedVIEW fork camera with barcode ccanning gets to the root of a previously unsolvable basic logistics problem and offers a practical and effective solution. Every large warehouse has a WMS that decides where and when goods are taken out of, or put into storage and reordered. It also manages the stock levels that determine the company’s ability to deliver. Feeding incorrect data into the WMS, therefore, has serious consequences. Today’s process of manual scanning from barcode lists or accompanying documents leads to master data errors in the WMS when goods are “incorrectly” stored /retrieved but “correctly” scanned.

The problem affects customers in all sectors, from trade and logistics to the manufacturing industry. It is particularly pronounced with reach trucks, as high-bay warehouses favour confusion due to their large number of uniform storage locations and the low visual clarity of upper rack levels. Depending on the type, 20-40% of reach trucks have tine cameras, are connected to a WMS via a radio data terminal and use hand-held scanners for booking. These customers will benefit considerably from the innovation.

In addition, working with the system is much faster and more ergonomic for every customer because there is no need to handle the hand scanner. Thanks to an acknowledgement button mounted near the steering wheel, the hands can remain on the steering wheel and hydraulic controls throughout.

Customer benefits

The fully digital addedVIEW fork camera with barcode scanning brings significant benefits for the warehouse manager and the forklift driver. The warehouse manager benefits from the avoidance of “wrong scans” and the associated improved data quality in his goods management system.
The advantages are:

• Increase in delivery reliability, because stocks in the WMS are correct.
• Reduction of erroneous trips due to incorrectly retrieved goods.
• Reduction of search times due to incorrect storage locations from the WMS.
• Reduction of unnecessary storage and retrieval when it is discovered on the ground that the goods from an upper storage compartment do not correspond to the ones sought.
• Reduced inventory corrections during stocktaking. More stable production supply and follow-up processes.

The driver benefits from significantly increased image quality and the ergonomic acknowledgement function on the steering wheel.
The advantages are:

• Goods labels can be read right at the top of the storage compartment, incorrect goods are detected early and unnecessary retrieval from great heights is avoided.
• The hands always remain on the steering wheel and the hydraulic controls, there is no need to reach for the scanner, scan and put it back every time.
• No more searching for the right barcode in a barcode list at the rack foot; time is saved and potential errors are avoided.

Overall, hidden costs of searching and errors are eliminated – the new process is faster, more reliable and therefore significantly cheaper per pallet.