Warehouses operate at lightning-fast speeds, beating with a hectic pulse as workers use forklifts and other machinery to shuttle items from point A to point B.
“The speed of which stuff is happening and the way that information has to flow and how fast it has to go, it's really changed our environment,” says Ryan Donovan, President of States Logistics, on a recent webinar.
During this controlled chaos of product-in and product-out, every minute is critical. But how many of those minutes are unaccounted for in your operations?
Traditional labor management systems (LMS) only take you so far in understanding your operations. The best LMS not only tracks performance in real time but also provides data-driven insights to make productivity improvements in your warehouses.
But despite all the tools and technology at your disposal and switching between a dozen different systems and reports to find what you need, there are several key questions that you can't confidently answer. Such as:
Which operators have a pattern of long lunches or breaks?
Are there process improvements needed near loading doors to make processing mixed freight easier?
How long do specific customer tasks or indirect processes actually take?
Answering these questions could save you millions each year through productivity and continuous process improvements.
Enter: Activity Tracking.
What is Activity Tracking?
Effective activity tracking is one of the most powerful tools in achieving productive operations.
Whether you're managing a single site or a vast network of facilities, understanding how time is spent can dramatically skyrocket productivity, safety, and profitability.
Activity tracking involves monitoring and recording various tasks and operations within your warehouse. This could include everything from standard break times to more complex tasks like battery changes, reworking pallets, or damage clean-up.
By accurately tracking these activities, you gain visibility into how your workforce spends its time, identifying productivity strengths and areas needing improvement.
Unfortunately, this isn’t always a simple task. The data either doesn’t exist today or it’s locked in a system that you don’t have access to.
Why Does It Matter?
There's the adage "Time is money" in every business. So, you must invest time in activities that generate a positive ROI and make your business more competitive.
In warehouse and logistics operations, it's no different. There are hidden timesucks causing inefficiencies, lost productivity and improvement opportunities — and stress keeping site management up at night.
So, when every second counts, understanding where time is lost and where it can be optimized is key. Activity tracking helps identify inefficiencies and plays a significant role in enhancing safety and ensuring compliance with operational standards.
It allows you to:
Monitor Real-Time Operations: With simple QR Sign-On, you can see the current activity of every piece of material handling equipment (MHE) in real-time, offering a clear picture of what's happening on the ground at any moment.
Identify Trends and Patterns: Over time, activity tracking helps you identify trends, such as recurring downtime or specific tasks that consistently take longer than expected. This data is invaluable in making informed decisions that enhance operational efficiency.
Improve Accountability and Performance: By holding associates accountable and providing effective employee coaching, you ensure that everyone is adhering to processes and contributing to a more productive work environment.
How to Implement Activity Tracking in Your Warehouse
Implementing an effective activity tracking system involves a few key steps:
Configure Your Activities: Start by setting up default activities such as breaks and work times. You can also add custom activities like loading, waiting on paperwork, or damage clean-up to suit your specific operational needs.
Train Your Operators: Ensure your operators are familiar with the system, particularly when signing on via QR codes and switching between different activity types as they move through their tasks.
Monitor in Real-Time: Utilize a Warehouse Operating System keep an eye on the real-time status of your equipment and operators, ensuring that everything is running smoothly.
Analyze Trends Over Time: Use the data gathered to look at total lost time, breakdowns by activity, and performance by individual operators. This analysis will help you decide where to focus your improvement efforts.
Implement Operator Self-Coaching: One of the most powerful aspects of activity tracking is its ability to trigger automatic, real-time coaching for operators based on activity triggers, helping them correct issues on the fly.
See the Immediate Results: With a more structured and monitored approach, many organizations see a significant decrease in lost time and increased productivity.
Lastly, Dig Deeper with Video Alerts: For activities that seem to be slowing down operations, video alerts can show you exactly what's happening, whether it's a process breakdown, operator non-compliance, or equipment failure.
Ready to implement activity tracking in your warehouse?
Activity tracking is more than just a tool—it's a strategy for optimizing your warehouse operations. Providing visibility into every aspect of your workflow helps you reduce inefficiencies, enhance safety, and ultimately, drive profitability.
Whether you're just starting out or looking to take your operations to the next level, effective activity tracking is the key to unlocking your warehouse's full potential.
Start by configuring your activities and training your team today to see immediate improvements in your operations.
Want a step-by-step playbook to eliminate idle time, skyrocket productivity, and optimize warehouse labor costs? Check it out here.
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