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淘豆网网友近日为您收集整理了关于Bar Coding and RFID - The Key to Traceability and Safety in the Foodservice Supply Chain的文档，希望对您的工作和学习有所帮助。以下是文档介绍：Bar Coding and RFID - The Key to Traceability and Safety in the Foodservice Supply Chain Bar Coding and RFID:The Key to Traceability and Safetyin the Foodservice Supply ChainA P P L I C A T I O N W H I T E P A P E RCopyrights 2004 ZIH Corp. All product names and numbers are Zebra trademarks, and Zebra and the Zebra logo are registered trademarksof ZIH Corp. All rights reserved. All other trademarks are property of their respective owners.Unauthorized reproduction of this document or the software(来源：淘豆网[/p-4307857.html]) in the label printer may result in imprisonment of up to one year andfines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.E x e c u t i v e S u m m a r ySafety concerns, competitive pressures and regulatory requirements are creating demand for more traceability inthe foodservice industry than ever before. Meeting the challenge does not have to be a burden on your business.Bar code and radio frequency identifi(来源：淘豆网[/p-4307857.html])cation (RFID) technologies can provide traceability and real-time controlto meet customer and regulatory requirements while actually improving efficiency and profitability.More extensive use of bar coding would produce $847 million in annual foodservice supply chain cost ording to a report by the Efficient Foodservice Response (EFR), an initiative sponsored by six industry tradeand anizations. An earlier EFR study found that improved item identifica(来源：淘豆网[/p-4307857.html])tion would provide thefoundation for logistics optimization, merce, inventory reduction and other improved businessprocesses that could drive $14.3 billion in non value-added costs from the foodservice supply chain.These savings are plished via accurate identification and data capture at all packaging levels wherever theinformation is needed in the supply chain to serve changing business process needs. To help you learn how togain these benefits, th(来源：淘豆网[/p-4307857.html])is white paper will: Demonstrate how improved product identification from bar code, RFID and related systems can createefficienc Introduce standards and technology options for item, inner pack, case, pallet and returnable con Describe how to take advantage of labeling and identification technologies to improve inventory, warehouse,distribution, returns, recall and route accounting operations.I n t r o d u c (来源：淘豆网[/p-4307857.html])t i o panies in the foodservice supply chain, especially small and midsize enterprises, will have to changetheir business processes to meet new safety and traceability requirements. The U.S. Food and Drug Administration’sproposed rule plying with the Bioterrorism Act of 2002 requires lot codes or other similar identificationfor food products. The EU Food Safety Law 178/2002, scheduled to take effect in Europe in 2005, requirestraceability of food, l(来源：淘豆网[/p-4307857.html])ivestock and any substance incorporated into them through all stages of production anddistribution, including records of to whom products were sold or distributed. These regulations will requirebusinesses to produce and manage more information than ever before. Doing so in a timely and cost effectivemanner practically requires the use of automated data collection.The systems used to provide the required documentation can also improve business respon(来源：淘豆网[/p-4307857.html])siveness and efficiency.For example, pany in the baking industry reduced its inventory and distribution costs by $3 million in thefirst year after an automated pallet labeling and identification system was installed. pany, which operatessix warehouses throughout the U.S. and previously was not able to measure and balance inventory throughoutits operations, began printing and applying bar code labels to all its cases and pallets and then scanning the(来源：淘豆网[/p-4307857.html]) barcodes to capture quantity, location and product identification numbers, including lot codes.1The system enabled pany to gain an accurate, timely view of inventory and to increase the averagenumber of pallets per shipment from 47 to 61, a 30 percent improvement. By increasing load yields, pany significantly reduced the need for expensive less-than-truckload (LTL) shipments to customers tofulfill orders, which contributed greatly to its cost savin(来源：淘豆网[/p-4307857.html])gs.Shortly after the system was implemented pany had to recall some products because it had receiveda bad batch of ingredients from one of its suppliers. Using the lot number information captured from bar codescanning, pany traced its shipments and conducted a highly targeted recall by contacting only thosecustomers who had received the affected products. The recall pleted quickly, with minimized cost, andwithout having to pull unaffected products f(来源：淘豆网[/p-4307857.html])rom store shelves.These results are typical among Zebra’s customers and help explain the profitability advantage that panies have over the rest of the industry. The best performing foodservice distributors have pre- profitof 2.0 percent, which is ten times higher than poor performers, according to a study by the Food DistributorsInternational (FDI), an industry group that now operates as the International Foodservice Distributors Association(IFDA). Top performers also have more than three times the asset efficiency of poor performers (13.0 percent vs.4.2 percent) and have total operating expenses equal to 14.7 percent of sales, a 2.2 percent cost advantage overthe others. Food and panies with best-in-class supply chain performance hold 60 percent lessinventory than median performers, according to a separate study by Performance Measurement Group thatdefines best-in-class performers as those in the top 20 percent of the industry.Automatic identification and data collection systems help create these advantages by preventing costly mistakes.Bar code data collection, for example, is far faster and more accurate than manual methods. Product codes, lotnumbers, invoice data, order numbers and other information can be recorded in less than a second with a barcode scan. Gathering this information manually is time consuming, because the information first must berecorded at the point of activity, then later transcribed and entered into puter system. The redundantmanual data recording procedures provide two opportunities to incorrectly record the information. Studieson data input accuracy conducted in the bar code industry found that an experienced typist makes one errorapproximately every 300 keystrokes. The 2003 Grocery Manufacturers Association (GMA) Logistics Studyfound that errors occur in 36 percent of consumer packaged goods orders. The same study found only 92.6percent of food and grocery products in the top 25 categories are available on store shelves for sale at anygiven time, which indicates supply chain problems and lost revenue opportunities.Errors create direct costs and have immeasurable effects on customer satisfaction and future sales. Let’s considerthe effect of mon shipping error in which an employee picks the wrong SKU to fulfill a customer order.The customer might discover the error while validating the shipment at receiving, and would engage the deliverydriver to help resolve it. If the error was discovered later it would result in a call to the supplier’s sales orcustomer service department.In either case, the distributor is incurring labor charges to research and correct the mistake. Involving the driverat the time of delivery could create delays that would cause him to miss delivery windows with other customers,causing additional problems and possibly creating the need for an additional, rush shipment from the distributioncenter. The customer will hold up payment of the invoice until the error is resolved, slowing the cash cycle.These actions, which all trace back to a preventable warehouse picking error, can have a significant impact onproductivity and profitability if they e an accepted part of doing business. Best-in-class performers are11 percent better than the average food and pany, have 90 percent shorter lead times yet consistentlymeet 100 percent of their mit dates according to the Performance Measurement Group study.2C a l c u l a t i n g Y o u r C o s t o f E r r o r sConsider a pany that earns a 3 percent profit margin makes an average of only one shippingerror per day (which is a very conservative estimate considering the GMA study found 36 percent of orderscontain at least one error). If each error takes 20 minutes to resolve, pany spends 10 hours a month onerror resolution. If the average wage for pre-sales and delivery personnel, customer service representatives andwarehouse workers is $25 an hour (which does not include shipping expenses), the monthly labor cost forerror resolution is $250. At a 3 percent profit margin, pany must make $8,333 in new sales to offsetthe monthly cost of errors.The table below shows a sampling of the revenue required to offset the errors based on different profit margins(x axis) and error resolution costs (y axis).Revenue Required to Offset Error Expenses2%* 5% 10.72%** 15% 20%$5 $250 $100 $47 $33 $25$10 $500 $200 $93 $67 $50$15 $750 $300 $140 $100 $75$20 $1,000 $400 $187 $133 $100$25 $1,250 $500 $233 $167 $125* An FDI study found that top performing panies have a 2% profit margin.** 10.72% is the average profit margin of S&P panies.To see the impact of errors on your profitability, first multiply the number of shipping and fulfillment errors ur each day by the time required to resolve each error.Next, multiply the daily time required for error resolution by average hourly wage of personnel involved in errorresolution. This sum is the daily labor cost of error resolution.Multiply the daily sum by the number of work days per year to get the annual cost of error resolution. Anotherway to arrive at this figure is to multiply the total number of orders filled in a year by the estimated error rate.The resulting figure represents the number of erroneous orders processed. Multiply it by the time required toprocess each error to calculate the total annual time spent on error resolution. Multiply this total by the averagehourly wage of personnel involved in error resolution to get the dollar cost.Now you have a measure of the annual direct labor expense attributed to error resolution. Note that this figuredoes not measure the impact of productivity losses, customer dissatisfaction, lost repeat business and otherpotential negative consequences resulting from distribution errors.Once the annual dollar cost of error resolution is calculated, divide it by profit margin to find revenue requiredto offset errors. For example, if error resolution costs $1,000 annually and you have a profit margin of 25 percent,the additional revenue needed to offset the cost of errors is $1,000 ÷ 0.25, or $4,000.3Here are some formulas to help quantify the cost of errors on your business.Impact of Error Resolutions on Profitability[Number of errors per day] x [Time required to resolve each error] = N, daily error resolution time (expressin hours)N x [Average hourly wage of employees involved in error resolution] = Y, direct daily labor cost for error resolutionY x [work days per year] = Z, annual labor cost for error resolutionZ ÷ [profit margin] = Revenue required to offset annual cost of errors.I m p r o v e m e n t O p p o r t u n i t i e sThe errors and expenses described above could have been avoided by accurately identifying items picked forshipment with a bar code scan and verifying it with a warehouse management or order management system.The principles of identification and validation can be repeated in many supply chain operations to improvetraceability and accuracy. The EFR study mentioned earlier found that the bar coding of products could save$152 million annually for manufacturers, $466 million for distributors and $226 million more for operators.The following sections highlight some of the best opportunities to improve operations with bar code plementary technologies.Lot ControlPutting lot numbers and expiration dates in a bar code makes it easy to record the information accurately andautomatically at any point in the supply chain. This capability improves data accuracy, while reducing the effortneeded to record and transcribe the information. Production management, enterprise resource planning, environ-mental health & safety monitoring and other systems frequently provide or require lot-level traceability, whichmeans the supply chain may be the only area where the information is not readily available. As we saw in theexample of the essful, batch-oriented recall, lot-level supply chain traceability is extremely valuable.Lot numbers may be encoded into bar codes and applied to pallet-, case-, inner pack- or item-level packaging.Expressing the information as a bar code in addition to human-readable text enables it to be scanned andprocessed by automated systems. Inventory management systems, for example, could use variable lot codeor best-by information to reduce waste by ensuring first-in, first-out (FIFO) procedures are followed.Encoding a lot number provides another level of identity that will help the industry meet traceability requirements.The globally standardized UPC/EAN bar codes used on products, and their associated case codes, are extremelylimited in their ability to provide traceability information because they only identify the manufacturer, producttype and packaging level, but do not uniquely identify each item. An additional identifier is needed, such asadditional information encoded on the pallet label. Reduced Space Symbology (RSS) is a relatively new barcode format developed to allow variable information, such as lot codes or best-by dates, to be encoded ongrocery items in addition to provide the information necessary for checkout operations, all within pactbar code label.4Cross DockingCross docking is a warehouse management technique that can significantly reduce storage and handling costs—providing the industry with $830 million in savings according to an EFR study conducted in 2000. In crossdocking, ing goods are identified at receiving and immediately routed for outbound shipping, withoutbeing placed into warehouse storage. Cross docking does not work if materials can’t be identified quickly urately, making bar code use essential for the operation.Mobile bar code label printers are especially valuable for cross docking. Shipping and receiving workers equippedwith puters, bar code scanners and label printers can receive inbound shipments, log them into thehost warehouse or inventory control system with the puter, then immediately generate a bar codeshipping label with the required cross dock information using the mobile printer, which may be mounted to aforklift or worn on a belt or shoulder strap. Some mobile printers can also connect directly to wireless LANs munication between the host system and the warehouse worker.RFID can also facilitate efficient cross docking. ing pallets or cartons with smart labels can be automaticallyrouted for cross docking or delivery directly to the manufacturing line because the fast-reading capabilitiesenable instant identification of the shipping container plus all of the individual items inside. For shipping, RFIDreaders can help packers quickly locate and aggregate all the items needed plete the load.ReceivingCross bines receiving, putaway and shipping operations to minimize product handling. Each ofthese traditional steps can also benefit by identifying materials with bar code or RFID. For traditional receivingapplications, a bar code label on ing shipments can be scanned to record the item’s arrival. Manifest dataor information from an Advance Ship Notice (ASN) electronic data interchange (EDI) message can included onthe label in a 2-D bar code or smart label to provide more detailed shipment information. Shipment identificationinformation can be forwarded to the warehouse management system, typically over a wireless LAN, whichrecords the arrival, updates inventory records and provides putaway instructions to the receiving worker. In thisway all materials are tracked automatically and accurately.The absence of bar codes on cases, and poor quality symbols on cases that are labeled, presents a major obstacleto efficient warehouse operations in the foodservice industry. Only about 64 to 83 percent of cases delivered tofoodservice distribution centers are bar coded according to EFR. Many of the cases are marked with low qualitybar code symbols printed directly on the corrugated packaging material, which are often unreadable. Printing barcodes on separate labels that are applied to the packaging dramatically increases read rates and improves overallsystem performance.Given the tremendous value of bar code-based warehouse management operations, and the relative ineffectivenessof supplier bar coding efforts, foodservice distributors would be well served by installing bar code labelingequipment to mark ing materials at the receiving area. Bar code label printers are rugged enough to beused anywhere within the warehouse and can connect to host systems through a variety of interfaces, munication for use in areas not wired puting working. Bar code label printing systemsare inexpensive to operate, have the flexibility to connect to any puter, network and software system,and can significantly improve the performance and return on investment of warehouse management, inventorycontrol and shipping systems.5Warehouse ManagementImproved warehouse management was rated the top advantage of using bar codes in an EFR survey offoodservice distributors. The advantages of bar code-based warehouse management systems are confirmedby the EFR research data, which found improved warehouse operations could provide more than $1 billionin savings to the industry.Bar coding and RFID improve warehouse management by clearly identifying product and making it easyto accurately record all stock locations and movements. Bar coding and RFID are typically used with ware-house management system (WMS) software packages, which perform a variety of functions to improve laborproductivity, documentation and efficiency. For example, a basic function of a WMS is to calculate the mostefficient picking and putaway sequences, which will reduce required labor and handling. When supported withtimely, accurate information, a WMS can manage inventory by expiration dates to reduce spoilage. Many WMSpackages can also help generate required shipping labels, EDI transactions and other required documentation.anizations, particularly in the retail and consumer goods industries, are beginning to use RFID smartlabels in their distribution and logistics operations. Suppliers, who will be required to provide products labeledwith RFID, can also take advantage of the technology in their own operations. work of RFID readers canbe installed to cover the facility and automatically detect and track item movements. The system could issuealerts when items are stored in the wrong location and can also provide security tracking. RFID also enablesitems to “self report” their locations, rather than requiring human intervention to find them, thus saving labor.mon bar code shipping application is to scan each case and pallet being loaded for transport to verify thatall required items are included and to prevent items from being loaded onto the wrong truck. A wireless municates the bar code scans to the puter, pares the items being loaded to theactual customer order. Incorrect or missing items are immediately detected and shipping personnel are notifiedwith a wireless message. Shipment accuracy often exceeds 99 percent when bar code data capture and real-timeverification are used.The foodservice industry could expand this application to enhance safety and traceability by automaticallycapturing lot codes and expiration dates from outgoing items. The lot and expiry information could be appendedto the record of the customer order. In the event of a shipment discrepancy or recall, the distributor would havethe documentation needed to trace specific lots to specific customers. The lot codes or other variable informationabout the cases in a shipment could all be encoded in a two-dimensional bar code applied to the pallet, which thelogistics provider and anization could read with a single scan to gather information about the entirecontents of the pallet.RFID provides similar functionality because every tagged case or package can be scanned simultaneouslywithout requiring the pallet to be opened, a feature that is central to many of the cross docking and otherlogistics advantages RFID can provide. At the point of shipping, as for receiving aggregated loads, RFIDprovides the highly desirable function of automatically recording what’s on a pallet (irrespective of whether thegoods are all of the same type or mixed), creating an electronic manifest of goods shipped or received. This is aunique and powerful core feature of modern RFID systems now being applied to retail supply chain operations.6Container ManagementUsing automatic identification systems to track pallets, milk cartons, trays and other returnable containers canprovide a strong return on investment by lowering operating expenses. Many producers and distributors do nothave accurate information about the quantity and location of their shipping containers because the assets oftendwell at customer facilities and aren’t returned promptly. As a result, businesses purchase more returnablecontainers to ensure they have an adequate supply, creating excess capacity and locking capital into fixed assets.Identifying returnable containers and tracking them to customers provides the information businesses can useto improve returns and recoveries. The first step is to permanently identify each asset with a bar code label orRFID tag. The assets can be scanned as they are loaded onto trucks at the distribution center, or in the field upondelivery. The information could be recorded in a database field in the customer record or order managementsystem, or in a separate database. Returned assets would be scanned to check them back into the distributioncenter, similar to a video rental return.Managers could consult the system software to get a real-time view of container availability. Outstandingcontainers could be tracked by customer, with documentation provided to aid return and recovery. By activelymonitoring and managing container usage, businesses can improve cycle times and inventory turns, and lowertheir fixed asset base.Recall ManagementFood recalls are a near daily occurrence and distributors need to have plans and processes in place to executethem quickly and efficiently. The degree of traceability suppliers and distributors have over their products iswhat determines the size, scope and expense of a recall.The amount of information included on unit-of-use packaging can make the difference between a general, massrecall with notices going out in newspapers and TV news, and a highly targeted, limited recall where customersmay receive notification by a phone call from their supplier. By including lot codes with shipping labels andother product identification, and marrying them with customer order and shipping records, businesses municate a recall like this: “We are recalling 8-ounce packages Ourbrandpasta, lot number ,made on March 19, 2003, between 8 a.m. and 1 p.m. on production line 2 at our Anytown, NJ facility. Theseproducts were shipped to Fictional Foodservice Distributor warehouses in Memphis, TN and Columbus OH.No other products are affected.” The distributor could then execute its part of the rollout in a similar fashionby tracing the affected products to specific customer locations.Production control systems and auditing procedures enable manufacturers to isolate quality plianceproblems at the lot level. By making lot-level traceability available throughout the supply chain with a bar codescan, specific quantities and shipments can be recalled. This degree of traceability limits the logistics handlingcosts and administrative burden, so recalls can be resolved more quickly. The audit trail would also limit liabilityexposure and prevent lawsuits from unaffected individuals. When returned products are received, lot codes canbe checked efficiently with a bar code scan, so unaffected products can be redistributed quickly.Returns ManagementVariable information unit-of-use printing could have similar effects on returns management, although thebenefits should be greater and more immediate because returns are part of every producer’s and distributor’severyday business. Returns may be subject to numerous local and national regulations regarding safe handlingand transport, documentation and traceability. One of the best ways to collect the information and create the7audit trail required to satisfy these regulations is to scan items with bar code readers, which can easily beprogrammed to attach a date-and-time record to every transaction. Scanning all movements and transfers andapplying an automatic time-and-date stamp creates traceability and produces tremendous time and labor savingsfor data recording.By setting shipping or database systems to record shipments to customers by specific lot number, manufacturersand distributors can verify that they are receiving authorized returns by quickly scanning an item label. Thispractice could also help detect unauthorized or counterfeit products. Scanning expiration dates will panies to determine if products are eligible for return and if returned products can be redistributed or requiredisposal or special handling.Route AccountingA variety of route operations can benefit from puting and printing technologies. Using these toolsto automatically calculate and print accurate, legible invoices can eliminate many billing disputes that are costlyand time consuming to resolve. Mobile technologies can also manage inventory on trucks accurately, removemanual, redundant data entry from ordering and billing processes, and even improve the payment cycle.Printing invoices at the time of delivery gives route sales drivers the opportunity to review them with customers,providing many of the same benefits as receipt printing. Adding on-site payment processing will have a significantimpact on cash flow. When invoices are prepared at headquarters the customer won’t receive them for severaldays because of processing and mailing time. Invoicing customers on site with mobile printers provides animmediate improvement to the payment cycle and requires less administrative support at headquarters forinvoice preparation.The cash-cycle advantage can be accelerated significantly by using mobile printers to accept payment on delivery.panies routinely wait 30 days or more to pay invoices. Requiring payment on delivery eliminates thebilling lag time and invoice processing delays, improving the cash cycle by at least a month. Mobile printerswith integrated credit card readers make it convenient and simple to accept mobile payment and improve cashflow. To learn more about the benefits of mobile printing for invoicing, receipt generation and other operations,download the white paper, Improving Field Sales and Service with Mobile Printing Operations from the IndustrySolutions pages at
d e n t i f i c a t i o n a n d L a b e l i n g O p t i o n sOnly a few different bar code formats are needed to execute the numerous applications described above.Thermal bar code label printers have the flexibility to produce all the required symbols and label formats,on materials that hold up in food storage and transport environments, which enable businesses to automatemultiple operations without making repeated investments in specialty equipment.Application planning and development can be greatly simplified mitting to the EAN.UCC System forproduct identification and management. UPC/EAN bar codes on consumer goods are just ponent ofthe EAN.UCC System, which provides a standardized method to accurately identify all levels of product pack-aging at every point in the supply chain. The EAN.UCC System that has been developed, standardized andadministered by the Uniform Code Council (UCC) and the European Article Numbering Association (EANInternational). It enables bar code, EDI, merce, XML and other identification municationmethods to be used together to provide accurate, automated traceability munications. The followingsections describe how label printing and the EAN.UCC System can benefit foodservice supply chain operations.8播放器加载中，请稍候...
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Bar Coding and RFID - The Key to Traceability and Safety in the Foodservice Supply Chain Bar Coding and RFID:The Key to Traceability and Safetyin the Foodservice Supply ChainA P P L I C A T I O N W H I T E P A P E RCopyrights 2004 ZIH Corp. All product names and numbers are Zebra trademarks, and Zeb...
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