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The Challenges of Scanning Pallets in the Warehouse


Efficient pallet scanning is critical for maintaining seamless warehouse operations, ensuring accurate inventory management, and minimizing disruptions in the supply chain. However, the process of scanning pallets presents a variety of challenges that can lead to significant business problems. From shipping and receiving errors to undetected product damage to delays at loading docks to excessive dock door real estate needs, warehouses face several hurdles that impact the accuracy, speed, cost and effectiveness of pallet scanning. Here we will explore some of the most common challenges associated with pallet scanning, including the risks of undiscovered product damage, delays at loading docks, the importance of real-time feedback, and the limitations of traditional RFID and barcode reading technologies.

How to improve pallet scanning efficiencies

Undiscovered Product Damage on a Pallet

One of the most pressing challenges in pallet scanning is the risk of accepting or shipping pallets with undiscovered product damage. In fast-paced warehouse environments, damaged goods can easily go unnoticed, This can happen when pallets are stacked or wrapped tightly, preventing warehouse workers from seeing the condition of individual products. If damaged goods are not detected during the scanning process, they may be accepted into inventory or shipped to customers, leading to significant financial and reputational consequences.

Ramifications of Accepting or Shipping Damaged Goods

  • Customer Dissatisfaction: If damaged goods are shipped to customers, it can lead to returns, complaints, and loss of trust in the company.
  • Increased Costs: Accepting damaged products into inventory increases costs associated with handling returns, restocking, and potentially scrapping the damaged items.
  • Operational Disruptions: Dealing with damaged goods requires additional labor, time, and resources to correct the issue, which can slow down other warehouse operations.

The lack of visibility into product damage using traditional pallet scanning methods highlights the need for more advanced technology like PalletSCAN systems, which can detect damage in real-time and alert warehouse staff before the products are received or shipped.


Delays at Loading Docks Due to Inefficient Pallet Processing

Loading docks are the heartbeat of any warehouse, and delays in processing pallets at this critical point can have a domino effect on the entire warehouse operation.  Whether caused by slow scanning methods, outdated equipment, or manual errors, delays at the loading docks create bottlenecks that disrupt shipping schedules and extend lead times.

  • Missed Shipping Deadlines: Delays in processing pallets can lead to missed shipping windows, affecting delivery timelines and customer satisfaction.
  • Increased Labor Costs: When loading dock operations are delayed, workers may need to work overtime to catch up, increasing labor costs.
  • Congestion: Delays at the loading docks can cause a backlog of trucks waiting to load or unload, leading to congestion and inefficiency in warehouse operations.
  • Decreased dock door utilization and increased real estate needs: Delays at the loading docks also tie up a dock door by taking longer to unload or load a truck, which can result in an increased need for dock doors and dock space for a given operational velocity. 
Loading dock delays

PalletSCAN systems speed up the pallet scanning process at loading docks, ensuring that pallets are processed efficiently and that trucks can move in and out of the facility without unnecessary delays.

Impacts of inaccurate pallet scanning can hurt productivity

Impacts of Inaccurate Pallet Scanning

Inventory Discrepancies – Without real-time verification, incorrect counts can lead to inventory discrepancies, resulting in stockouts or overstocking.

Shipping Errors – Shipping the wrong products to customers can lead to increased return rates, customer dissatisfaction, and additional shipping costs.

Delayed Order Fulfillment –  If incorrect goods or quantities are detected late in the process, it can delay order fulfillment, leading to longer lead times and missed delivery deadlines.

Accurate scanning is essential for pallet processing, and technologies such as computer vision can provide immediate confirmation of goods and counts, reducing the risk of errors.

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Limitations of RFID and Barcode Scanning for Pallets

RFID and barcode scanning technologies have long been the standard for tracking and processing pallets in warehouses, but they come with significant limitations that hinder their effectiveness in modern warehouse environments.

  • While RFID can scan multiple items at once, it is prone to interference from metals, liquids, and other materials commonly found in warehouses. Additionally, RFID requires specialized tags that can be costly to implement and maintain.
  • Warehouse barcode scanning is highly manual, requiring line-of-sight scanning and human intervention. This slows down the process, increases the risk of human error, and is impractical for high-speed operations.

In contrast, PalletSCAN systems eliminate the need for tags or manual scanning. They can automatically recognize and process multiple pallets at once, improving both speed and accuracy while reducing operational costs.

Pallet scanning with RFID is challenging

PalletSCAN computer vision systems deliver the TRUTH to your WMS

The Visual TRUTH of Your Inventory

Because Vimaan uses warehouse computer vision, we are capable of processing more than barcodes, including 2D codes, alphanumeric text, images and more.  And because we use computer vision we are capturing thousands of digital images of the inventory as they are being scanned.  Vimaan image stitching software than instantly combines these images into comprehensive digital twins of your inventory.  These high-resolution images are easily retrieved and reviewed through the ViewDECK web application allowing warehouses to use them for on the fly discrepancy analysis and to resolve customer order disputes.  RFID and barcodes are incapable of delivering any visual proof of your goods at the time of scanning.

The challenges associated with pallet scanning in warehouses—such as undiscovered product damage, delays at loading docks, and the lack of real-time feedback—can create significant operational and financial risks. Moreover, traditional RFID and barcode technologies have limitations that make them less effective in addressing these issues. To overcome these challenges, warehouses are increasingly turning to PalletSCAN, which offers real-time visibility, accuracy, and speed, helping to streamline pallet processing and improve overall efficiency.

Pallet Scanning Automation Guide

As warehouse operations scale, the complexities surrounding pallet tracking and management increase significantly. Whether it’s verifying product SKUs, ensuring shipment accuracy, or optimizing warehouse space, pallet scanning plays a pivotal role in maintaining order and reducing costly errors.

Computer Vision and Machine Learning Application Resources

Automated pallet scanning demos

The Most Powerful Family of Pallet Scanners in the Warehouse

See firsthand how this diverse set of pallet scanning systems solve the most common and time intensive warehouse challenges including:

  • Fast barcode scanning and text reading
  • Ti-Hi Counting and SKU Verification
  • Non-stop drive through pallet dimensioning
  • Reconcile items that do not belong
  • Inspect for damages and more!
  • Get a custom pallet scanning system demo and discover how Vimaan can help improve pallet processing quality and speed, while reducing your operating costs,

 

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