Recent innovations include pick-for-store order processing for major multiple retailers with integration of advance shipping notices to simplify fulfilment processes and shorten lead times, logging food safety compliance processes, and refinement of voice-enabled picking to improve productivity to even higher levels.

Ian Render, operations manager at Winterbotham Darby, explains: “Many of our processes are based around the warehouse and the WMS is pivotal because it gives us the ability to control stock on a real time basis. Working with our demand and supply planning system it helps us ensure the availability of product to maximise service to our customers. We integrated Empirica to ensure those processes are supported by a robust structure that works well.”

The company originally implemented Empirica in 2008 to RF-enable stock management processes at its main warehouse in Redhill. Voice-enabled order picking, added in 2012, led to an increase in productivity. This utilises verbal instructions issued by Empirica and responses made by warehouse operatives wearing headsets. There is no need for RF scanners during picking and this 'hands-free' aspect of the operation is one of the key reasons why productivity is enhanced. Although the underlying processes are standardised, each operative interacts with the system using a unique profile that can be tailored to their language, vocabulary and speed of working. 

Over time the company recognised that it could shorten many of the standard phrases used by the system to minimise the time needed to receive instructions and confirm actions. It also identified that numeric check digits were more efficient than alphabetic. These changes led to incremental improvements in picking rates with no impact on accuracy. The latest wireless headsets have highly efficient noise-reduction capabilities that eliminate many misunderstood instructions, again leading to small gains in performance.

“Voice picking has been hugely beneficial,” says David Bettison, group WMS manager at Winterbotham Darby. “Our labour resource has remained static for the last 18months, during which time we have seen volume growth which has been achievable due to the voice picking solution which has continued to provided productivity improvements and operational efficiencies. We are however constantly reviewing the existing RF and voice solutions to ensure we are utilising all elements to maximise the benefits to the operation.”

Information drawn from business applications including Empirica has helped Winterbotham Darby reconfigure the warehouse layout so that frequently-picked lines are closer to the marshalling area. Pick-paths are optimised so that, on average, operatives walk shorter distances between each pick. This reduces the time required to pick a full order.

In recent years Winterbotham Darby has implemented Empirica at its Deli Solutions and Alatoni businesses. Each operation has a unique set of requirements that place different demands on the WMS. The company is keen to keep its processes as simple as possible by using a common platform at all sites. One of the key benefits of Empirica is its ability to provide greater stock visibility which, combined with the company’s Lake View ERP and FuturMaster Supply Chain Management applications, supports improved stock availability for customers. As retail lead times continue to shorten, the ability to fulfil orders consistently, quickly and predictably becomes a critical business objective.

“Empirica provides a number of reports, including full allocations and short orders, and supports back picking which makes our operation more versatile,” explains David Bettison. “Picking later in the day is possible which enhances our ability to fulfil orders quickly. Empirica also reports on labour and productivity so we can identify who does what, when and where. With these tools we can manage expectations.”