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Oznium Warehouse Automation - Transformed in 6 weeks

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Phil
Owner, Oznium.com

Joined: Feb 11 2003
Posts: 7719


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Post Sun Sep 26, 2010 9:25 pm

What I've been up to...

Full text and tons of pics, CLICK HERE:
http://www.philsuslow.com/phil/warehouse-automation/


Basically:
6 weeks of crazy intense work at the warehouse/office. Lots of cool automation & technology.

Followed by a fun 2 week luxury road trip through Europe (scroll to bottom), and then a month or in Bali.

A trippy time-lapse video of Julie picking 30 orders last Saturday:
Tim

Joined: Nov 16 2003
Posts: 10795
Location: Kalamazoo, MI


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Post Sun Sep 26, 2010 9:58 pm

love the cart idea. great use o a ipad. wanna share what url it browses to?
Phil
Owner, Oznium.com

Joined: Feb 11 2003
Posts: 7719


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Post Sun Sep 26, 2010 11:10 pm

Here's a static html page of an example pick list.

Optimized for iPad screen of course.
Tdawgthegreatest

Joined: Jul 22 2007
Posts: 5093
Location: Florence, Oregon


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Post Mon Sep 27, 2010 12:32 am

Very cool Phil. Warehouse is coming along, and nice pictures from your recent adventures!
PwrRngr

Joined: Jul 19 2007
Posts: 4407


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Post Mon Sep 27, 2010 3:18 am

Very cool,well done, and inovative updates. In the event that you have shipping personal issues in the future, it should make training much easier.

Not sure if it's just my computer, but when I try to enlarge the Warehouse layout picture (under "Warehouse Layout & Organization") I get a 404 error.
domestic_disturbance

Joined: Dec 18 2003
Posts: 1621
Location: Columbia Missouri


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Post Mon Sep 27, 2010 6:17 am

looks like everything is coming along great!
a little more advanced that it was 5 years ago when alot of us first moved over here from the SG forums eh?
alkatmsu

Joined: Nov 08 2005
Posts: 1560
Location: Kentucky


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Post Mon Sep 27, 2010 6:23 am

Hope your employees know not to pick their nose/scratch themselves while packing a customer order... would be hilarious, yet embarrassing to have a picture of that show up on that customer page. Other than that, looks like you've got an awesome system!
A-Ray

Joined: May 01 2005
Posts: 4062
Location: Volunteer State


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Post Mon Sep 27, 2010 7:26 am

Seeing this makes me think about how awesome it would have been to work for you.
Tim

Joined: Nov 16 2003
Posts: 10795
Location: Kalamazoo, MI


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Post Mon Sep 27, 2010 8:06 am

The idea that when a user's order is weighed it's photographed three times from three different angles and then stored with their order # in a database is awesome. The amount of time and effort that went into ensuring that each customer is getting exactly what they ordered, I would expect nothing less from Oznium.

I have to say, the idea of each bin having an IR LED and an alarm going off if the picker reached into a box that didn't correspond with what the current order they were filling was sounds familiar, like something Amazon would do.
Tat2Dragons

Joined: Jan 21 2007
Posts: 3404
Location: Baltimore Maryland


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Post Mon Sep 27, 2010 11:11 am

Extremely cool! icon_cool.gif
Bobby Lee

Joined: Mar 01 2003
Posts: 3881


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Post Mon Sep 27, 2010 1:05 pm

Holy hell, Phil! Very freaking cool. This sure is leaps and bounds ahead of the shelfs and computer you had at your house in Cali. icon_biggrin.gif
corvettecrazy

Joined: Dec 17 2003
Posts: 4357
Location: moved (twice)


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Post Mon Sep 27, 2010 1:44 pm

I can't be the only one wondering about the day the packing person wears a v neck or low cut shirt....

I love the change and innovation in that though.
Chris

Joined: Sep 27 2004
Posts: 2395
Location: NY


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Post Mon Sep 27, 2010 6:59 pm

Can you hire me now? Okay maybe Ill just come out and look at it.

Nice job. You're a multi-talented man with programming all that.
Aken

Joined: Feb 12 2003
Posts: 10885


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Post Mon Sep 27, 2010 7:18 pm

None of the orders I packed ever had errors. icon_biggrin.gif
The_Mastor

Joined: Jan 23 2006
Posts: 4195
Location: Idaho


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Post Mon Sep 27, 2010 10:12 pm

These are awesome innovations icon_cool.gif I'd love to work for you as well, seems like a fun place icon_lol.gif
02BlueStang

Joined: Dec 13 2004
Posts: 4757


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Post Tue Sep 28, 2010 4:01 am

Great job Phil...enjoy your much needed vacation looks beautiful over there icon_cool.gif
Phil
Owner, Oznium.com

Joined: Feb 11 2003
Posts: 7719


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Post Wed Sep 29, 2010 8:45 am

Thanks for the feedback guys.

Preliminary numbers are in, and looking quite good!

System implemented mid-August. Numbers refer to the percent of orders.

Shipping Error - Wrong Product Received
June: 2.58%
July: 3.22%
August: 0.95%
September: 0.4%

Product Never Received (now mostly USPS error - just gets lost)
June: 1.38%
July: 4.63%
August: 2.04%
September: 0.3% (all 'never received' September orders were lost by USPS)

Product Broken in Shipping (not really affected by barcode system)
June: 0.6%
July: 1.2%
August: 0.4%
September: 0.5%



Detail of September shipping errors:
1) Customer clearly ordered warm white, but they insist they ordered cool white. Not Oznium error. But we're honoring replacement anyways.

2) Customer ordered 2 foot, but we sent 1 foot. The package was labeled incorrectly by factory.

3) Pigtail power leads were missing from a customer's Piranha bar. The product description doesn't necessarily say the product includes pigtail leads. But another Piranha bar on the customer's order did have pig tails, and so they assumed they should be included with every Piranha bar. It would be quite simple though for the customer to just snip off the plug and hook up the wires. I guess some people are scared of this for whatever reason. We ended up just sending another pigtail wire.

4) Customer placed a phone order for 3 Orange floods, but Justin accidentally put the order in for Green. Shipping department accurately shipped Green. But we ended up having to replace for the Orange that customer originally wanted. This doesn't happen too often, but one option to eliminate this would be forcing the customer to order online (and only then accepting the credit card details over the phone). But probably not worth the hassle - errors like this are rare.



Will now start addressing the defective product rate icon_smile.gif
PwrRngr

Joined: Jul 19 2007
Posts: 4407


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Post Wed Sep 29, 2010 9:23 am

Dramatic improvements! Very cool.
Tim

Joined: Nov 16 2003
Posts: 10795
Location: Kalamazoo, MI


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Post Wed Sep 29, 2010 10:43 am

Numbers look good.
bad venge

Joined: Jul 28 2007
Posts: 3550


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Post Wed Sep 29, 2010 11:48 am

Did the three orange floods come out of Justins Pay ???
Tdawgthegreatest

Joined: Jul 22 2007
Posts: 5093
Location: Florence, Oregon


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Post Wed Sep 29, 2010 1:00 pm

corvettecrazy wrote:
I can't be the only one wondering about the day the packing person wears a v neck or low cut shirt....

I love the change and innovation in that though.


x2
Bobby Lee

Joined: Mar 01 2003
Posts: 3881


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Post Wed Sep 29, 2010 2:24 pm

Statistics and numbers say a lot. Keep it up Oznium team!
kramer13
Oznium Employee

Joined: Jun 20 2004
Posts: 3744
Location: Baltimore, MD


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Post Sat Oct 02, 2010 2:00 pm

The work Phil put into this system is amazing.
kramer13
Oznium Employee

Joined: Jun 20 2004
Posts: 3744
Location: Baltimore, MD


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Post Sat Oct 02, 2010 2:02 pm

bad venge wrote:
Did the three orange floods come out of Justins Pay ???


*checking bank account*
domestic_disturbance

Joined: Dec 18 2003
Posts: 1621
Location: Columbia Missouri


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Post Sat Oct 02, 2010 4:11 pm

kramer13 wrote:
bad venge wrote:
Did the three orange floods come out of Justins Pay ???


*checking bank account*



lol, better check it twice just to be sure
Chris

Joined: Sep 27 2004
Posts: 2395
Location: NY


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Post Tue Oct 05, 2010 8:21 pm

How did you come up with all of this stuff? Were you the only one working on this?
Phil
Owner, Oznium.com

Joined: Feb 11 2003
Posts: 7719


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Post Tue Oct 05, 2010 11:13 pm

My Dad helped pretty much everyday for the 6 weeks. And had a perl/unix expert help with the scale integration for a day or two. And a local camera installer ran wires/mounted the cams. And of course the employees + some extra help with moving stuff around/labelling.
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