Barcodes are more than just lines and spaces. They are the core of automated data entry, warehouse management, and stock optimization. And no matter what size your business is, understanding the basics of how barcodes work can give you powerful tools to track inventory and make your whole operation more effective.
In this article, we'll look at where barcodes came from, how they help run warehouses, what makes different barcode scanners unique, and how barcodes boost efficiency. So, if you're aiming to make your inventory counts more accurate or to speed up data entry, this article will teach you how to use barcodes to get the most out of your warehouse.
Here’s a full overview of the topics we will be covering in this article:
The history of barcodes
The origin of the barcodes dates back to 1948 when two Drexel University students, Norman J. Woodland and Bernard Silver, tried to solve supermarket checkout and inventory management problems. Good ol’ Morse code inspired them to create a bullseye-shaped design (the original design looked more like circles inside of circles.)
Also, though this new idea showed promise, it didn’t work well then because of tech limits.
Early beginnings
Woodland and Silver stuck with their invention. They got a patent for their barcode idea in 1952. It wasn’t until the invention of the laser in 1960, however, that technology finally enabled automated barcode reading, setting the stage for barcodes to transform inventory and warehouse operations.
In 1974, someone scanned the first UPC barcode on a pack of Juicy Fruit gum at a Marsh store in Troy Ohio. This kicked off when barcodes started showing up everywhere – and hasn’t stopped since.
How warehouses use barcodes today
It's quite remarkable that a technology from 1948 still sees widespread use today. Barcodes have a crucial impact on current warehouse operations. They speed up and increase the accuracy of inventory tracking and management. Warehouses now use barcodes to enhance processes such as receiving, storing, picking, and shipping goods. Software platforms like warehouse management systems (or WMS) also enable warehouses to gather data with barcodes in real-time. This helps cut down on mistakes and boosts how well the warehouse runs.
How barcodes work
Encoding information
A barcode influences how information is stored in a visual pattern that machines can read. This pattern consists of parallel lines of different widths – called linear or 1D barcodes – or more intricate designs like rectangles or dots in 2D barcodes. Every change in width or pattern stands for different characters, boosting the range of information that can be encoded, from plain text to websites and pictures. An example of 2D barcodes that have grown in popularity? QR Codes.
Scanning process
Scanning a barcode involves several essential parts: a light system, a sensor, and a decoder. The light source, often a red LED or laser, shines on the barcode and bounces off it. The sensor then picks up this light and turns it into an analog signal. The decoder then changes this signal into text using a check digit to ensure the barcode is read right. This text is then processed and matched with product info stored in a database, which helps with tasks like keeping track of inventory and managing it.
Types of barcode scanners
Handheld scanners
Handheld barcode scanners are small devices you can operate with one hand (get it? Hand held.) They come equipped with a trigger that can be pulled to scan, and come with or without cords. The scanners work by using laser or imaging tech to read the different types of barcodes like 1D, 2D, and postal codes. As you can imagine, these scanners are useful in many places, from stores to factories, because they can do so many things.
Industrial scanners
Industrial barcode scanners are tough versions of handheld scanners and are built with strong materials to handle rough environments. (You can think of it like this: Handheld scanners are like iPhones. Industrial scanners are like the indestructible Nokia from the early 2000s.)
Industrial scanners also often come with an IP rating, which shows that they resist things like dust and water, making them perfect for use in rugged environments like factory floors or outdoor work areas.
Mobile scanners
Mobile barcode scanners, also known as mobile computers or handheld terminals, combine computer capabilities with the mobility of a scanner. These devices can connect and send data through different networks like Wi-Fi, WAN, and Bluetooth. They also have extra features, like GPS, that boost their usefulness. Mobile scanners are handy for jobs requiring movement, like package delivery or field work, where access to real-time data is crucial.
How logistics and retail businesses use barcodes
Barcodes can help different industries in many ways. Let's look at some examples of how barcode technology can boost logistics and retail businesses.
Logistics
Barcode technology plays a key role in making supply chains work better for logistics companies. It enhances the tracking of goods throughout the delivery process, from manufacturing to distribution. Barcodes give instant updates and accurate data, which companies need to handle stock and get products to buyers on time. Using barcodes in logistics also helps firms follow rules in fields like food where keeping tabs on products is key to ensure they're safe and good quality.
Retail
Barcode technology has a positive impact on retail operations. Scanners that read barcodes give access to product information, which helps to improve stock management, maintain price accuracy, and quicken the checkout process. This tech allows stores to categorize products using different barcode types such as UPC and QR Codes to keep tabs on them.
What's more, stores can use mobile barcode scanners to handle inventory from afar, which proves useful for businesses with large or multiple inventories. Stores make fewer errors and boost customer satisfaction because orders are more precise and the checkout goes faster.
How barcodes boost warehouse management
Barcodes boost warehouse management by making various operational processes more efficient. Here's how warehouses use them across different functions:
Using barcodes for receiving
When goods arrive at a warehouse, barcoding ensures quick and accurate data capture. This cuts down on paperwork and lowers the chance of mistakes. Scanning barcodes during the receiving process confirms transactions and reduces errors that come with manual data entry.
Using barcodes for picking
Barcodes have an essential role in the picking process. They enable quick and dependable item verification. This speeds up work and cuts labor costs. How? By reducing the need for manual checks and lowering the number of workers needed for operations. Also, using barcodes in picking processes allows exact measurement of productivity. It helps track how well individuals and departments perform. This, in turn, improves overall productivity.
Using barcodes for serialized items
In industries where tracking and traceability matter – like pharmaceuticals and food and drink – barcode serialization plays a key role. This process gives each item its own unique code letting companies follow it from creation to delivery. This boosts safety and helps meet rules set by regulators. It also makes managing recalls easier and keeps safety standards high.
Zenventory also supports barcode scanning. This feature makes these tasks simpler and works well with systems that manage warehouses. It allows for instant updates to inventory and precise tracking of goods as they move through the supply chain. This teamwork helps keep operations smooth, cuts down on mistakes, and boosts how well things work overall.
Putting barcodes into action in warehousing
Checking out technology
Before you start using a barcode system in your warehouse, you need to take a good look at your current tech setup and infrastructure. You should check out what kinds of goods you handle, how often they move, and how many transactions you deal with. This check will help you figure out the right tech and gear you need, like barcode scanners and label printers making sure they fit with how your warehouse works.
Step-by-step guide
- Planning: Begin with an evaluation of your current inventory management methods to spot areas where barcode tech could boost productivity and precision.
- Choosing the right system: Pick a barcode setup that matches your warehouse operations. Think about things like how many items you handle, how complex your inventory is, and what the environment is like in your warehouse.
- Implementation: Put the barcode system into action across all warehouse operations, including inventory management, receiving, and shipping.
- Training and SOPs: Teach your employees how to use the new system well. Create Standard Operating Procedures (SOPs) to keep things consistent and reduce mistakes.
- Integration with software systems: Make sure your barcode system works well with your current Warehouse Management System (WMS) to update inventory in real-time and manage data.
Barcodes & Warehouses: FAQs
Barcodes and warehouses go hand in hand, like peanut butter and jelly. They just work better together.
But when it comes to barcode technology in warehousing, there’s still a lot to unpack. Below are some frequently asked questions to help you better understand how barcodes power smarter, faster operations.
How do barcodes actually work, and why are they so reliable in warehouses?
Barcodes convert information into a visual pattern that machines can quickly scan and decode. In warehouses, this means faster product identification, fewer manual entry errors, and real-time visibility into inventory locations and quantities – all of which help streamline operations.
What equipment is needed to set up barcode scanning in a warehouse?
You’ll need barcode labels, scanning devices (like handheld scanners or mobile devices with built-in scanners), and inventory management software (like Zenventory) to process the scanned data. Many warehouses now use mobile apps that combine all these functions in one easy-to-use system.
What types of barcodes are most common in warehouse environments?
The most common are 1D barcodes (like UPC and Code 128) and 2D barcodes (like QR codes and Data Matrix). 1D barcodes are great for simple tracking tasks, such as identifying SKUs. 2D barcodes can hold more information, making them ideal for more detailed logistics workflows.
Making things better with barcodes
Tracking in real-time
Barcodes make it easier to track high-value assets by connecting each item to essential data like when it was bought, maintenance records, and warranty information. This doesn’t just simplify managing assets – it also means all the vital information is easy to find, cutting down on mistakes when people track things by hand. When barcodes aren’t accurate because of human slip-ups, it can cost a lot. Luckily, barcodes help keep track of things.
Managing inventory
Using barcode systems in inventory management allows for real-time visibility and increased accuracy. Barcodes make it easy to capture and integrate data quickly, keeping tabs on inventory levels, tracking inventory movements, and adjusting stock based on up-to-the-minute information. This setup helps a lot in cutting down on storage costs and speeding up turnover by ensuring you have just the right amount of inventory without having too much or running out.
Also, when you use systems like Zenventory, barcoding scanning becomes crucial to how you work, making inventory management more accurate and efficient.
Cutting down on human mistakes
Whenever someone has to enter data by hand, mistakes happen. (We are human, after all.) Research shows that humans make a mistake in one out of every 300 characters they type, which adds up to about 18 errors per hour. Barcodes cut down on these mistakes big time. They offer a fast and trustworthy way to capture data. When someone scans a barcode, the data is automatically collected, eliminating the need for manual entry – and the human errors that come with it.
Speeding up data collection
Barcodes make data collection faster, a major key to running warehouses well. It takes about two seconds to find and scan a barcode. So, you can do up to 1800 scans in an hour – much faster than typing the information by hand. Barcodes also help process orders faster, reduce running out of stock, and keep customers happy by ensuring inventory counts are spot-on.
On top of that, Zenventory’s barcode scanning feature makes these jobs even more effortless, boosting real-time inventory tracking and making the whole operation run smoother.
How Zenventory can help
Zenventory takes your barcode scanning capability to the next level by integrating with your warehouse management system, allowing for real-time inventory updates and accurate tracking. This integration makes receiving goods easier, doing cycle counts, and picking items for customer orders.
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