$250,000 in frozen food went bad because of one simple mistake?
A major food producer used a popular warehouse management system (WMS) for its freezer warehouse. Like most WMS programs, it required an employee to manually scan each pallet and dock door before the pallet is loaded onto the trailer. One day, the fork truck operator didn’t scan his last pallet into the trailer properly, closed the dock door and went home for the night. The WMS knew the load was only 95% complete, so it was waiting for the last scan, but it didn’t have an alert notification feature to let anyone know the trailer’s status. The only way to check whether a load was “complete” was to scroll over to a column on the far right of one screen! So 12 hours later, after the reefer unit ran out of fuel, the load partially thawed and the entire $250,000 in prepared TV dinners had to be thrown away.
With 4SIGHT Dock Management …
Any truck that sits past a certain escalation time triggers visual alarms on 4SIGHT’s graphic interface, and the system sends an email alert notification to management. And because 4SIGHT knows when a dock door is prematurely closed while a trailer is still attached to the warehouse, this odd condition could have been used to trigger the alert before the escalation time alert.