4 Sided Pallet Scanning with PalletSCAN 360
Warehouses are capturing all 4 sides of pallets faster than ever before with PalletSCAN 360.
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Efficient pallet scanning is critical to warehouse operations, particularly as supply chains become more complex and businesses demand faster, more accurate inventory management. Historically, two primary technologies—Radio Frequency Identification (RFID) and barcode scanning—have been employed to track and scan the contents of pallets. However, advancements in warehouse computer vision have made it a superior choice over RFID and traditional barcode systems, offering increased accuracy, visibility, flexibility, scalability, and lower long-term costs. Here we highlight the reasons why computer vision powered systems, like PalletSCAN, outperform these older technologies for pallet scanning in warehouses.
Computer vision systems leverage sensors, high-resolution cameras, advanced image recognition algorithms, and artificial intelligence (AI) to capture, analyze and store visual data in real-time. This results in a level of accuracy and granularity that is unmatched by RFID and traditional barcodes.
While RFID can read multiple tags simultaneously and doesn’t require direct line-of-sight scanning, its accuracy is often compromised by interference from metal racks, liquids, or other dense materials commonly found in warehouse environments. Additionally, RFID tags can malfunction, and the technology is prone to data inaccuracies due to cross-reads (when an RFID reader picks up signals from nearby tags unintentionally).
Traditional barcode scanning requires a manual line-of-sight process, which is time-consuming and prone to human error. It can only capture limited information, typically a product identifier or SKU, rather than detailed, multi-faceted data that can support inventory management and real-time decision-making.
In contrast, computer vision systems like PalletSCAN 360 capture detailed images of pallets and their surroundings, identifying and processing each pallet with unparalleled accuracy. They can recognize product types, SKU’s, count individual units, and detect damaged goods—all in a single pass. Another advantage that the PalletSCAN computer vision system has over RFID systems is that it is able to “filter out” stray signals that may originate from neighboring pallets in the receiving, shipping or storage location. RFID readers do not have the ability to discriminate whether the signal is coming from a particular pallet or the one behind it or adjacent to it.
One of the other advantages of warehouse computer vision technology is its ability to fully automate the pallet processing workflow, significantly reducing the need for human intervention.
Both RFID and barcode systems require workers to handle or direct scanners toward specific locations on a pallet. Even though RFID is more automated than barcodes, it still demands some manual effort to ensure proper tag placement, avoid signal interference, and monitor the system for errors. Further, once a tag has been used, if the warehouse or distribution center attempts to reuse it, significant inventory housekeeping procedures and software upgrades are needed to differentiate between successive scans of the same tag that may represent totally different pallets. Alternatively, if tags are just used once, it introduces additional process steps to affix the tag to each case on the pallet – which entails both increased labor as well as cost.
With Vimaan computer vision, once cameras and systems are installed, the technology is easily integrated into existing processes and initiate real time feedback. This automation frees up labor resources, minimizes the chance of errors associated with manual processes, and allows workers to focus on more strategic tasks. Additionally, computer vision systems can be integrated into robotics, conveyors, or other automated systems to further streamline operations.
Vimaan computer vision-based scanning not only identifies pallets and contents, but also results in more comprehensive visibility into pallet and case attributes – such as lot numbers, serial numbers, expiry dates, country of manufacture, pallet dimensions, Ti-Hi case counting, damage, etc. All this information is generated in real-time, providing more data and enabling more powerful analytics for warehouse managers. This ability to analyze data in real-time leads to faster decision-making and more responsive warehouse operations.
While RFID readers can capture data relatively quickly, it lacks the ability to provide in-depth insights beyond basic identification information. It is limited in its capacity to offer real-time visual confirmation of pallet conditions or inventory levels.
Barcode systems are even more limited in real-time data processing. Barcodes are scanned and processed individually, which means that it’s difficult to get a holistic view of warehouse operations without additional manual inputs.
PalletSCAN computer vision, on the other hand, can provide real-time insights by validating pallet contents, count cases and detect for damages. PalletSCAN is easily integrated with the warehouse WMS or other system of record to give warehouse operators immediate access to inventory levels, workflow bottlenecks, and efficiency metrics, leading to more optimized warehouse operations.
Realtime scanning analysis with PalletSCAN identifies issues instantly
Vimaan computer vision is inherently more versatile than RFID and barcode systems. It can process a wide range of pallet types, sizes, and configurations without needing specialized tags or barcodes. This flexibility allows warehouses to accommodate various inventory types without overhauling their tracking systems.
In contrast, RFID and barcode technologies often require standardized tags, labels, and scanning positions, which can be a limitation in dynamic warehouse environments with diverse product assortments.
Not only can Vimaan systems (like PalletSCAN 360) capture all the required case and label data, they also digitally photograph the sides of the pallet. These digital photos provide warehouses with visual proof of a pallet’s condition when it was received or shipped from the warehouse. These images are available in the Vimaan ViewDECK web application that provides inventory visualization to warehouses and are extremely helpful in quickly resolving customer disputes.
In contrast, RFID and barcodes cannot “see” the pallets, thus limiting their ability to provide actionable insights to warehouses.
The PalletSCAN suite of computer vision systems offers numerous advantages over RFID and traditional barcode systems in warehouse pallet processing. Its superior accuracy, ability to automate processes, real-time data capabilities, cost-efficiency, and versatility make it the ideal solution for modern, high-performance warehouse operations. As warehouses evolve to meet increasing demands for speed and efficiency, computer vision stands out as the superior choice for processing pallets and managing inventory.
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