Reducing Errors and Improving Accuracy With Automated Sorting in Logistics

How Automated Sorting Reduces Errors in Logistics

Automated sorting systems optimize sorting and enhance productivity without requiring additional labor through accurate, highly configurable technology.

Barcode Scanning

Automated sorting systems use scanners to capture data from 1D and 2D barcodes at reliable read rates. This technology identifies the product and retrieves all associated information from the warehouse management system (WMS). Fixed-mount barcode scanners capture data accurately regardless of the items’ orientation as they move through the system.

Integrated Weight Verification Capabilities

Integrated weight verification capabilities accurately measure the weight of each package and compare it to predefined parameters. If the item records a higher or lower weight than the specified figure, the system automatically diverts it for inspection. This process addresses common fulfillment errors, including: 

• Incorrect quantities in an order
• Missing items in a package
• Wrong items

Automated Routing

After the barcode scanner accurately identifies the item and confirms the weight, the sorting system determines the product’s route based on WMS instructions and physically guides it to the designated place. This location could be a packing station, storage area, or truck loading bay.

Automated routing directs items to their designated locations, improving efficiency and providing more accurate delivery estimates for reliable tracking.

Benefits of Automated Sorting in Logistics

Operations professionals face increasing pressure to maintain accuracy and meet the growing demand for faster deliveries, all while managing potential labor shortages. Automated sorting enables warehouses and distribution centers to keep pace and enhance customer satisfaction.

These challenges require logistics automation solutions that provide:

• Enhanced accuracy: An automated barcode/RFID scan tunnel with fixed-mount readers provides reliable identification and verification, improving order fulfillment accuracy.
• Reduced labor costs: Automated sorting handles repetitive manual tasks, letting your team focus on higher-value work and maintaining productivity through labor shortages without increasing labor costs.
• Improved scalability: Automated sorting systems are scalable through additional bins and configurable system capacities, allowing your business to adapt to fluctuations.
• Enhanced work safety: Automating strenuous, repetitive sorting tasks improves employee safety and job satisfaction. 

Reducing Logistics Mistakes With OPEX^® Automation

OPEX^® leverages decades of experience in automation solutions to provide several automated systems for logistics accuracy improvement:

• OPEX Sure Sort^® automated sorting system
• OPEX Sure Sort^® X sorting system
• OPEX Sure Sort^® X with Xtract™ retrieval system
• OPEX Cortex^® sort-to-order^™ software

Item Identification and Verification 

Invest in sorting solutions with a barcode/RFID scan tunnel that identifies and verifies items with the WMS. Integration with your warehouse management system provides real-time item status and traceability, reducing mis-sorts.

Weight Verification 

OPEX automated sorting solutions support integrated weight verification capabilities, enabling your team to catch discrepancies before packing and maintain order accuracy.

Automated Routing

iBOT^® robotic vehicles navigate the system to deliver packages to the correct sort bins in a single pass, reducing the need for manual sorting. Pick-to-light LEDs notify your team when orders are sorted.

Sure Sort X with Xtract automates tote retrieval and content transfer to shipping containers, minimizing human errors and mis-packs.

Handling and Traceability

To further increase accuracy, our solutions offer:

• Automated return conveyor: The system automatically recirculates items with verification issues to exception bins for rescan and inspection based on WMS instructions.
• Hand scanner support: Operators resolve damaged or ambiguous labels immediately with manual scanning, updating the WMS record, and clearing the exception.
• Piece-level tracking: Capture images and data and create a chain-of-custody record for complete item traceability.
• Software audits and alerts: Cortex software features built-in quality control checks to flag missing items or delivery discrepancies.

Start Reducing Errors in Logistics With OPEX

Reducing errors and improving accuracy with automated sorting in logistics is possible with OPEX sorting systems. OPEX’s in-house technical team offers comprehensive support from configuration to implementation, including training and 24/7 technical support.

Contact OPEX online today to schedule a demo and see the impact of improving order accuracy with automation.