Rugged Systems for Warehouse Applications: Making Smart Investments in Technology

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1 Rugged Systems for Warehouse Applications: Making Smart Investments in Technology

2 Warehouses were early adopters of mobile computing technology. Rugged mobile terminals and barcode scanners have been in place in one form or another in the warehouse and distribution industry for more than four decades. These supply chain and mobility solutions have a multitude of benefits for warehouse operations; however, if you aren t using rugged hardware built to handle harsh environments, you could face excessive downtime caused by the need to replace or repair your mobile devices. The number and variety of mobile device options increases constantly, and market growth has accelerated rapidly over the past decade. Device types range from relatively inexpensive smartphones with a significant amount of computing power in a small form factor, to highly rugged tablet computers that can withstand being run over by a truck and just about every permutation in between. Warehouse operators and other end users may be tempted by the lower purchase price or flashier interfaces of consumer-grade smartphones or tablets and attempt to deploy them in a warehouse environment. In the long run, this is a mistake. For enterprise applications where operators work in harsh environments like inside warehouses or in the warehouse yard, rugged devices typically have a much lower total cost of ownership (TCO) despite their higher purchase price. 2

3 The Case for Rugged Mobile Computers Unlike their consumer-grade counterparts, rugged terminals and tablets can withstand extremely harsh and challenging conditions including extreme temperatures, dirt, dust, liquids, and multiple drops. Because of their design, the rate of failures for a rugged device is typically much lower. According to a 2013 article in PC Magazine, rugged devices have a 2% average failure rate, compared to non-rugged laptops, which had a 12% failure rate in ideal environments. Ruggedness Ratings The relative ruggedness of a mobile computer is often expressed in two common ratings: the IP rating, and the MIL-STD rating. The IP (Ingress Protection) number, with the first digit referring to protection against dust and the second to protection against liquids. An IP65 rating provides complete protection against both types of contaminants. The MIL-STD ratings cover exposure to high and low temperatures, high altitudes, shocks, rain, humidity, leakages, and sand/dust exposure. Beating the Heat (and Cold) Warehouses expose computer equipment to a wide range of operating temperatures. Rugged mobile computers are built to withstand the sudden changes in temperatures when moving from very hot to very cold environments without creating condensation which would be the case in a warehouse that handles frozen food or other cold chain applications, for example. In some cases, these devices are designed with built-in heaters to make sure the internal components aren t damaged by lengthy exposure to low temperatures. 3

4 Built to Last These devices can also withstand multiple drops to concrete, as well as other sources of shock and vibration. Because these computers minimize the number of moving parts (no fans or rotating drives), they are in a better position to survive the rough treatment they experience in a warehouse. The Zebra TC8000, for example, can keep operating reliably after 2,000 consecutive hits when tumbling and multiple 8-foot drops to concrete. Rugged computers can also survive exposure to chemicals, solvents, and cleaners. The plastics and other materials in the computer are selected because they don t break down when exposed to chemicals. Non-rugged devices can crack or break. Because they are built to last, rugged computers also have a much longer lifecycle, typically four to six years, compared to the two-to-three-year life of a consumer device. Over time, you could wind up buying more consumer devices just to refresh the outdated hardware, and that doesn t even take into account replacing broken or damaged devices. Rugged device warranties also reflect their expected usage, with coverage for the types of accidental damage that will be experienced in those applications. Another key differentiator is battery life. Rugged computers are meant to be used for a full eight or 12- hour shift and are equipped with robust batteries that can be hot-swapped while the device is in use and rapidly recharged. With consumer smartphones and tablets, certain applications can rapidly deplete the batteries, which then take a long time to charge. If the batteries are not removable or accessible (which is the case with many popular smartphones), the device is rendered unusable while it charges. That potentially increases the total number of devices required to maintain productivity across a single shift. 4

5 The Case for Rugged Mobile Computers (Continued) Built-In Flexibility Rugged computers are also sold with added functionality that can support your warehouse operations and increase productivity. Most come with embedded Wi-Fi modems, wide-area wireless connectivity, and/or embedded GPS technology, for example. They also support common mobile device management (MDM) solutions, RFID or barcode scanning, and other warehouse management system (WMS) features. Many of these devices also support terminal emulation (TE) so that they can be used to access legacy warehouse software. Indoor/Outdoor Applications Rugged computers can be used by workers both inside and outside the four walls of the warehouse, in any conditions. Ergonomic designs decrease weight and limit fatigue for employees who use these devices for the length of a shift. Specially designed buttons or touchscreens allow use even while workers are wearing gloves. These computers can also be carried, worn (in a holster or shoulder strap) or placed in a vehicle mounting dock, making them extremely versatile. Finally, the displays can be read in both bright daylight or in very dark conditions, meaning the same devices can be used in the yard or in poorly lit storage areas. The displays are also designed and treated to be highly resistant to scratches and shattering, both of which are common problems with consumer device displays. 5

6 Rugged Barcode and RFID Scanners The need for ruggedization applies across all classes of warehouse hardware. As with mobile computers and tablets, rugged barcode and RFID scanners are built to withstand harsh industrial environments and to have extended battery life. Rugged mobile devices typically have enterprise-grade barcode and RFID scanners built into the device. The onboard scanners in a smartphone or other device may not provide the scan speed required for a busy warehouse. Sled-style attachments can be used with some phones and tablets, but these add cost and an additional point of failure. Rugged barcode scanners are also built for heavy use. They offer a longer read range so that users can scan barcodes on high shelves or from a forklift, even at a relatively great distance. An example is Zebra s DS3500-ER scanner series, which allows scanning of different types of barcodes from near contact to as much as 30 feet away. They can also provide more accurate scans at greater speeds. They are built with internal logic that allows them to read barcodes through shrink wrap, to decode damaged or partial barcodes, and are omnidirectional so that they can read the barcode in any direction and from any angle. Despite their rugged construction, handheld scanners are designed to be lightweight and ergonomic in order to keep workers productive and reduce the risk of fatigue or repetitive motion injuries. Phones and tablets, by contrast, are not built to be held in scan position for lengthy periods of time. 6

7 Rugged Printers The importance of ruggedization also extends to the label printers used in the warehouse. Many distribution centers use a mix of fixed-position label printers at shipping, receiving, or on mobile carts, along with mobile printers that can be used to create on-demand labels by workers at the point of activity. While consumer-grade options are available, rugged printers are built to withstand the same harsh environments, extreme temperatures, drops, shock, dust, and liquid exposure as rugged mobile computers and scanners. Fixed-position label printers are typically protected with an all-metal enclosure that is designed with the operator in mind. Employees can easily change media and perform routine maintenance without the risk of damaging the printer. These printers are also designed for fast operation in high-volume applications, and have a much longer lifecycle than consumer printers. Some barcode printers, if they are well maintained, can remain in service for a decade or longer. Rugged mobile printers can be worn or mounted on vehicles and are designed to work with common mobile computers. They can also survive drops to a concrete floor or exposure to dust or liquid. In addition, printers designed for industrial use can be integrated with your enterprise resource planning (ERP) system to enable centralized printer management, troubleshooting, and maintenance. 7

8 Compare Total Cost of Ownership Rugged mobile computers, printers, barcode scanners and other hardware required for your warehouse and inventory management applications are more expensive than their consumer counterparts. But you have to look beyond the upfront cost of the hardware when making your purchasing decisions. While consumer devices may be less expensive, in most cases they will create a much higher TCO than a rugged device. When you consider the totality of development, hardware refresh and replacement costs, deployment costs, repairs, and downtime, rugged devices will cost much less in the long run. Remember, procurement costs are only a small part of TCO. Even more critical is the cost of a failure at the point of activity, whether that s in a warehouse, or in a vehicle on the road, or in the field. When the device stops working, so does the employee using it. That downtime can have very costly repercussions, particularly in a warehouse. A broken mobile device can bog down picking operations or completely shut down a packing or shipping line. According to an analysis from VDC Research, failure rates for non-rugged tablets in line-of-business applications exceed 15% for tablets and 20% for smartphones; for rugged devices, those figures are less than 5% for tablets, and less than 10% for smartphones. TCO for non-rugged devices was nearly twice that of their rugged counterparts. There are also soft returns for using rugged devices. Your operation will experience fewer delays and failures, employees will be less frustrated, and productivity will increase. Consumer-grade devices in the warehouse are a gamble; while they may cost less, they pose a significant long-term maintenance and support challenge. Rugged devices, which have a proven track record in warehouse applications, are a safer bet. About RACO Industries RACO Industries is an industry-leading integrator of business solutions across barcoding, card, and GPS applications. From device configuration to network provisioning, equipment staging, kit delivery, solution implementation, and ongoing support, we make sure the solution addresses your business unique needs. For more information, visit our website: or call About Zebra Technologies Zebra makes businesses as smart and connected as the world we live in. Zebra tracking and visibility solutions transform the physical to digital, creating the data streams enterprises need to simplify operations, know more about their businesses, and empower their mobile workforces.