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SOLVED Supply Chain Challenge? Unreadable GTL Barcodes Create a Bottleneck
Global Transport Label (GTL) codes are ideal for package sorting but are susceptible to becoming unreadable. Engineering Innovation implemented a two-barcode system that enhances efficiencies.
processing ef ciency close to 100%. With faster sorting, reduced errors, and improved scalability, the client achieved peak ef ciency. In the words of our Engineering Project Manager, Eric Auberry, “Our great success came from a mistake.” The client was apprehensive at rst about our idea to add a second barcode, wor- ried that it would add time and delays to the overall operation. When a too- early software release threatened to become a challenge, it became a bless- ing in disguise. The high rate of unreadable GTL codes provided real-time data that per- fectly illustrated the need for the IMPB. Imagine a scenario where only 1 out of 10 packages were being sorted cor- rectly due to damaged GTL codes. With the two-barcode system software activated, the data showed the effective- ness of our solution. The IMPB codes ensured near-perfect accuracy, transform- ing the sorting process from a struggle to a streamlined success story. As Bob Ross would say, “There are no mistakes. Just happy accidents.”
THE CHALLENGE Sorting can be a high-pressure environ- ment. This is no different for one of our customers, a mail service provider con- solidating parcels for the United States Postal Service. When you are process- ing thousands of pieces an hour, speed and accuracy are crucial. Often, this critical task relies on a speci c type of barcode: the Global Transport Label or GTL code. These compact data matrix codes are great for holding a lot of information in a small space, making them ideal for pack- age sorting. GTL codes, despite their advantages, are susceptible to becoming unreadable due to several factors. Wrinkles in poly- bags, a popular choice of packaging used for their affordability and lightweight design, could distort the code, confusing barcode readers. Glare or hot spots from the package sur- face could obscure it entirely. Additionally, a printing malfunction known as ther- mal bleeding could cause the code to become distorted, overlapping the small lines within the GTL code and making it useless. Unreadable GTL codes cause major problems. The smooth ow of the sorting process grinds to a halt. Packages pile up, waiting for someone to decipher the dam- aged code manually. This was a slow and error-prone process, adding delays and frus- tration to our customer’s entire operation.
THE SOLUTION: A TWOBARCODE SYSTEM FOR UNMATCHED EFFICIENCY When our customer came to us with this problem, our team of engineers began researching how best to imple- ment a solution to decrease “No Read” rates. The answer came in the form of a two-barcode system and a reader that identi es both simultaneously. The GTL barcode remains the pri- mary source of information, holding all the essential data needed for sort- ing the package. In addition, we added an Intelligent Mail Package Barcode, or IMPB, as a safety net. This unique identi- er is less prone to becoming unreadable due to wrinkles, glare, or thermal bleed and points to a separate database to ef - ciently nd and sort, bypassing the need for a control person to manually verify illegible GTLs. Through our solution, which pro- vides redundancy, we signi cantly reduced bad read rates, bringing
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24 Inbound Logistics • May 2024
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