Barcoded Freight Labels

Conditions

Objectives

Label Design

Receiving

WHY FREIGHT TRACKING?
As a result of just-in-time planning, customers want to know where their shipments are at a moments notice. They now specify where, how, and when they want their product delivered. This creates higher performance expectations on carriers.

In order to achieve higher performance expectations, more sophisticated information technology is required. It is faster access to information about the location of shipments that creates the ability to achieve higher performance expectations. Information is the single element that links the various steps of the delivery chain together. Bar codes represent the means of tracking shipment location. As a by-product of this information, business processes can be reengineered to improve process and delivery efficiency. Bar coding provides the ability to track individual freight items faster and more accurately than keyboard entry, saving multiple hours of data delay. It provides real-time tracing of trailer unloading and loading. This results in a reduction in errors, time, and personnel required. Typical results are a 95% reduction in shipping errors and an operational savings in labor-intensive areas of 15% to 20%, saving multiple hours of data delay. It provides real-time tracing of trailer unloading and loading. Consequently more frequent and accurate tracking increases the visibility of each shipment location.

CONDITIONS:

Thousands of cartons and shipments in process.
Multiple trailers constantly in route. Cartons and shipments in various trailers en route to destination.
Multiple trailers unloading and loading LTL shipments transferred
Customers asking for status regarding shipments including when pick up occurred, current location of the shipment, when shipment was delivered, number of cartons, and who received the shipment

OBJECTIVE:
The objective of bar coded freight labels is to:

1. Increase the speed and the accuracy of data collection and the tracking of shipments

2. Improve the response time to inquiries regarding shipment status. They facilitate efficiency in data collection and freight processing in fully automated systems in the these ways:

paperless cross-dock operation:
Bar codes provide carriers with the means to operate a paperless cross-dock operation. This requires scanning terminals to be located at each receiving bay. As each trailer is emptied, the bar code pro label on the carton is scanned. Cartons are gathered by waybill and verified complete. As a result, real time data is collected and stored in the computer, providing information on line for staging and transferring to trailers cross-dock in the shipping bays for delivery. Further, with installed in-motion scanner conveyor sorting systems, cartons can be unloaded onto a moving conveyor, scanned and automatically sorted and accumulated into trailers for routing to the destination.
automated hub operation:
Automated hubs are another area where superior efficiency can be achieved. They can be configured with power takeaway conveyors at each receiving door that will merge freight into a central conveyor system. Multi-directional scanners mounted on high-speed tunnels identify freight. Accumulation conveyors gather shipments into lanes and release all pieces together, after the shipment has been verified as complete. Accumulated cartons for each shipment can then be routed in a unit to the awaiting trailer. Shipments can then be released in the proper sequence so that placement on the trailer matches the routing and delivery, thus speeding up delivery.

Shipments are linked to the specific trailer. This data is then loaded into the driver's scanners for final scanning and confirmation on delivery at the receiver's premises. The receivers name is keyed into the scanner for proof of delivery. On return to the terminal, the delivery data is downloaded into the system, closing off the shipment and ending the tracking process.

Because many customers require a written signature, delivery manifests are still being used. Over time, it is expected customers will accept electronic signatures in much the same way bar codes are accepted.

automated weight verification:
Freight is shipped and billed by weight. Carriers typically depend on the shippers' stated weight, though they usually reweigh about 10% as a sampling verification, at their dock. With the use of bar codes and automated conveyors, it is practical to weigh each piece while being transferred via conveyors. The bar code ties each piece to the waybill in one of two ways. In one method, the freight weight is not recorded until the piece is passed at conveyor speeds over an in-motion scale at the hub. Billing is generated at that time by actual weight, class and destination. The only requirement is that packages be separated one from another on the conveyor through the in-line scale. Optionally, the shipment is recorded by shipper weight. The actual weight recorded at the hub is compared to the shipper's stated weight. If the actual weight at the hub exceeds the shippers' stated weight, the shipper is billed for the corrected weight.
automated volume measurement:
Carton volume can be captured on the conveyor. By automatically capturing the length, width, and height via scanners mounted on the conveyor, the volume for each piece can be determined regardless of shape. As a result trailer capacity can be measured ensuring equipment is not overloaded. Freight charges for air cargo and other tariffs are controlled by density in pounds per cubic foot. This provides the carrier the information to determine whether the freight charges should be rated by physical weight or volume weight. This dimensioning capability operates at full conveyor speed, regardless of positioning on the conveyor. The only requirement is that packages be separated one from another through the scanning tunnel and the in-motion scale.
automated inquiry on delivery status:
Collected data is immediately stored in the computer. The bar codes are scanned at each step in the process…as the freight is picked up, transferred, and delivered, thus identifying the location and status of the shipment. This information is immediately available for inquiries by both those shipping and receiving the freight.

THE LABELING PROCESS:
Standard Pro books generally consist of a cover with driver instructions, a back cover of tag board or chipboard (to add stiffness to the book), 25 to 50 label sheets of bar coded sub labels, and possibly other shipment identification labels. Each of the subset labels on an individual sheet would normally have the same number. One sheet would be used for each Pick-up that a driver has. One label for Customer's Bill of Lading, One for Shipping Company's Bill of lading and the remaining two labels for the freight that is to be picked up.

1. Full cartons of pro labels are issued to terminals documenting box number, beginning and ending number, missing numbers and when it was sent.

2. Label sets are issued to drivers by the book, providing tracking documentation.

3. As the driver picks up each shipment, a sheet of bar coded labels is used for each shipment. Usually, a label set or sheet contains three to seven sub-labels all having the same number. As these identically numbered subsets are applied to various cartons and documents, they become the common thread by which tracking is achieved. The driver scans the bar code and transmits the shipment data via on-board communication systems to the centralized tracking computer to provide time specific shipment information. The transmitted information is used to assign the shipment to the best availible door. This reduces handling and improves cycle time. While shipments are being loaded into the correct trailer, the bills of lading are scanned and transmitted to a central billing area.
Depending upon the requirements of the particular freight company, the sub-labels within each sheet are applied differently. One of the sub-labels within the set is affixed to the shipper's bill of lading, one sub-label is affixed to the carrier's copy of the bill of lading, one or more sub-labels are applied to the cartons or pallets to be shipped, one on the driver's manifest. A label may also be used if the freight is interlined with another carrier. A label may be used to specially identify a shipment for return.

LABEL DESIGN:
Our freight pro label capabilities include:

A wide variety of standard sizes and options
Custom packaging
Customized programs including proprietary check digit calculations, computerized terminal number tracking; number blocking programs, etc.
Quality sampling reports on every box of pro labels.

The two key elements of a pro label system are high readability by the bar code scanner and the document scanner and the guarantee of having no duplicate numbers.

NEEDS	RESOLUTIONS
To maximize the readability of the numbers, bar code and Arabic.	Maximize the quiet zone space. Instead of matrix-removed construction, utilize butt cut construction. Increase the read rate of the optical scanner used to capture and digitally store the bill of ladings and proof of deliveries (PODS) by: Using butt cut construction to maximize quiet zone around the bar code Use non-scan inks to reduce print contrast ratio and eliminate the digital capture of artwork to minimize data storage requirements. Frequently, the PODS are variably imaged with the customer's statement to show delivery. It is difficult, but very critical to maintain the highest possible optical scanning rate to insure proper digital capture and storage of this data. Increase readability by incorporating a MOD check digit into the bar code. A mod check digit has a verification algorithm within it to check numbers within the code. This is particularly important if of a bar code was scuffed or printed poorly. Facilitate the reading of the human readable numbers by separating the check digit from the actual tracking number and/or splitting the human readable number into 3 digit segments. Frequently numbers used in pro label sets have many digits, 9 to 12 is not uncommon, including the check digit. This makes it extremely difficult to read the actual number. Varnish overcoat the bar code on the label to protect it from scuffing. Most high volume bar code labels are manufactured with toner-based variable imaging systems. Varnishing prevents toner picking and scuffing. This is usually available with inline imaging methods such as ion deposition, but not typically available with laser imaging systems. Utilize quality control systems during manufacturing which scan every carton of labels and attach printed results to each sample. This ensures, upfront, that there is a minimal chance of misprinted or poorly printed bar codes.
Poor bar code scanning occures because preprinted text on the carton shows through the label.	Use opaque adhesive on the label to increase opacity and decrease preprint show through.
No duplicate numbered label sets. Identical numbered label sets result in conflicting data about two shipments tracked by one shipment number.	Computer controlled printing.
All bar codes within a label set MUST have the same number.	Paginate set as one label with multiple numeric locations. Electronic printing eliminates skips associated with numbering machines. Paginating label set guarantees all sub-labels within a label set to have the same number.
Simplify the issuing and use of label sets to drivers and handling of label sets by drivers.	Booking in sets. This facilitates distribution to the drivers. Pro labels are typically booked in sheets of 25 or 50. The quantity is a trade off between the average daily pickups made by a driver and the economy of more sheets per book. Stitching is more secure and economical than padding. While not required, pro labels are typically booked with covers. Covers not only protect the labels, they also add stiffness to the book. The front cover is normally 100# tag. The face of the cover is variably imaged with the terminal number as well as the number series of the labels within the book.
Create an opportunity to capture data for potential new customers.	Print panel on reverse side of label set to list potential new sales leads.
Make the label set accessible to the driver at all times.	Design a size, including dimensions and thickness which will fit into the driver' shirt pocket.
Facilitate the easy removal of sub-labels from the label set.	Facilitate the easy removal of sub-labels from the label set. Use strip coated adhesive to leave a non-adhesive edge on the sub-labels thus allowing easy removal from the liner.
The label must adhere to corrugate, shrink-wrap, and paper.	Frequently high initial tack aggressive permanent adhesive is used to assure labels stick immediately to the carton or shrink-wrap.
Maximize the utilization of all label sets within the book. Because of the constant use of the pro label books and their convenient size, drivers frequently use the back of the book covers as their note pad, writing down the location of additional pick ups or deliveries. When this space is fully taken, many times the balance of the book is thrown away, simply so the driver can use a new cover for documenting new pickups or deliveries. This is an expensive note pad!	Preprint lines on the front and back of the back cover. This will allow the driver's to list more pickups and deliveries within the same space, thus reducing the loss of label sets when the books are thrown out. The Book Saver Feature. Insert an additional back cover with preprinted lines to provide additional "note" space for the driver. The additional expense of one ply of tag is significantly less than one sheet of label stock (one sheet in a book of 25 sheets represents 4%).
Minimize the time it takes to find and apply separate "hazardous material" labels or COD labels onto shipments requiring such labels. Traditionally, "HAZ MAT" or "COD" labels are kept inside the truck on rolls or sheets and used as required. When they are required, the driver must return to the truck cab, find the required labels, return to the shipping area, and apply the labels.	Include one combination sheet of "HAZ MAT" and "COD" labels in each book of label sets. This will eliminate the lost time taken when the driver must go to the truck cab, locate the labels, return and affix them to the freight.
Sometimes shippers and/or recipients require a delivery receipt.	Provide a sheet of delivery receipt labels within the pro book
Sometimes shippers require that label sets be applied to the shipment and then transferred to another location (i.e. from carton to document) at a later date.	Seated labels. Trap a sub-label within the liner. Apply the original label, and later remove it for relocation. This is significantly less expensive than piggyback label material.

QUALITY CONTROL:
Though not desirable, missing numbers are not typically a concern. The major concern is duplicate numbers or non-scannable numbers. With customer approval, we remove one or two label sets per box, scan the bar codes and print out the results. The results are stapled to the sample and forwarded upon shipment of the order. The readability of the codes can be verified before they are introduced into the system.

RECEIVING PRO LABELS:

NEEDS	RESOLUTIONS
Receiving pro labels can be a tedious effort. Typically, each terminal has a separate number series, requiring the cartons for each terminal to be separated and identified. Number series must be keyed into the computer.	Speed up the receiving process and the distribution process by bar coding the starting number and ending number on each carton label. Speed up the receiving process by bar coding the starting and ending number of each carton on each pallet packing list. By simply scanning the starting and ending number of each carton on the packing list, the entire shipment can be automatically loaded into the computer system.

NEEDS

RESOLUTIONS

Receiving pro labels can be a tedious effort. Typically, each terminal has a separate number series, requiring the cartons for each terminal to be separated and identified. Number series must be keyed into the computer.

Speed up the receiving process and the distribution process by bar coding the starting number and ending number on each carton label.
Speed up the receiving process by bar coding the starting and ending number of each carton on each pallet packing list. By simply scanning the starting and ending number of each carton on the packing list, the entire shipment can be automatically loaded into the computer system.

OTHER BAR CODES USED IN SHIPPING:
Today manufacturers, distributors, and retailers want to manage the supply chain more efficiently. They want to know much more than just shipping status and location. They want to know more than simply the product code. They want to know batch number, use by date, serial number and more. And they want it all in an automated format usable by everyone in the supply chain. This is achieved using bar codes with application identifiers, prefixes that are used to identify the information for which the bar code is being used.

EAN 128 symbology:
EAN 128 is the symbology standard for bar coding carton content information. EAN 128 is an open and very flexible standard. The concept is straightforward; encode, at the source, all information potentially used by those in the supply chain. Manufacturers, distributors, carriers and retailers can then extract the information they need. Beyond product information, EAN128 has the ability to provide logistics providers with information such as weight, cubic, quantity, delivery address, purchase order number, and serial shipping code number. The process requires that EAN 128 bar code labels be attached to each carton. When the shipment is received, carton data can be automatically and accurately captured into the recipient's database, facilitating shipment receipt and inventory control.
two-dimensional symbology:
The use of two-dimensional (2D) symbology, primarily PDF 417, is the hottest technology in transportation. The primary application is to encode the entire bill of lading for rapid and accurate data entry. This is the key to eliminating problems with freight bills. Traditional systems involve manually keying frequently extensive bill of lading (BOL) data at the freight terminal, resulting in frequent errors. A large percentage of invoices are rejected in computer systems for discrepancies and costly manual processing.

By encoding the BOL data in a PDF 417 symbol, the carrier can quickly and accurately scan in the BOL data at the terminal, reducing labor costs and nearly eliminating freight bill errors. Since the shipment information originated by the shipper is so accurate, shipments needed very little checking, compared to shipments without this coded information, which frequently sit in receiving until shipment detail errors are reconciled.

We manufacture pro label sets for many of the leading U.S. domestic carriers.