Warehouse Automation & Barcode Scanning FAQ
WMS Integration
How do barcode scanners integrate with a warehouse management system (WMS)?
Barcode scanners connect to a WMS either through WiFi-connected mobile computers running the WMS client app, or through USB/Bluetooth tethered to a workstation with the WMS installed. Enterprise WMS platforms such as Manhattan Associates, Blue Yonder, and SAP EWM are designed to drive Zebra and Honeywell mobile computers running Android. The scanner sends scanned data to the WMS, which validates the barcode against the inventory database and directs the worker to the next task.
Shop Warehouse Mobile Computers →What barcode symbologies are commonly used in warehouse environments?
The most common warehouse barcode symbologies are Code 128 (for shipping carton labels and GS1-128 logistics labels), GS1 DataBar, and QR Code or Data Matrix 2D codes for item-level tracking. SSCC (Serial Shipping Container Code) labels on pallets use GS1-128 and encode a unique 18-digit identifier. PDF417 appears on some WMS traveler tickets. Most modern 2D imagers on devices like the Zebra TC72 or MC9400 read all of these symbologies natively.
Shop Warehouse Scanners →Hardware Selection
What type of barcode scanner is best for a warehouse environment?
For picking and packing tasks, a mobile computer like the Zebra TC72 or Honeywell CT60 running your WMS app provides the flexibility workers need across large floor areas. For fixed conveyor or sorter scanning, use in-line or omni-directional presentation scanners that read in all orientations without operator intervention. Forklift-mounted vehicle-mount computers with ring scanners are ideal for receiving and put-away. Choose IP65 or higher rated devices for environments with dust, moisture, or wash-down cleaning.
Shop Warehouse Scanners →What is voice picking and do I need special hardware for it?
Voice picking is a WMS workflow where workers receive spoken instructions through a headset and confirm tasks by speaking keywords, leaving their hands and eyes free. Dedicated voice-directed systems use wearable computers like the Honeywell Vocollect A700 series paired with noise-canceling headsets. Many modern WMS platforms also support voice on standard Android mobile computers using Bluetooth headsets, reducing hardware costs while maintaining productivity gains of 15–25% over paper or RF-gun workflows.
Shop Warehouse Mobile Computers →Conveyor & Fixed Scanning
How do I scan barcodes automatically on a conveyor belt?
Fixed conveyor scanning systems use one or more stationary omni-directional laser or 2D imager scanners mounted above, below, or alongside the conveyor to read labels in any orientation as packages pass by. Tunnel scanning systems (zero-effort scanners) surround the conveyor from all sides to guarantee reads regardless of package orientation. These systems connect to the WMS or sorter controller via Ethernet and trigger on a photocell or weigh scale signal.
Shop Barcode Scanners →ROI & Planning
How do I calculate the ROI of a warehouse barcode scanning investment?
Start by measuring your current error rate (mis-picks, mislabeled shipments) and labor hours per 1,000 orders picked. Barcode scanning typically reduces picking errors by 67–80% and increases throughput by 20–25% over paper-based processes. Factor in the cost of hardware (mobile computers, chargers, printers), WMS software licensing, training, and ongoing device management. Most warehouse scanning deployments achieve payback in 12–24 months when error costs and labor savings are fully accounted for.
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