If you’re looking at ways to improve your warehouse processes, increase picking and packing timescales and run a more efficient warehouse, then you may, at some point, have thought about automation. But where to start? The choice in warehouse automation is vast and can range anywhere from a basic conveyor belt right through to complex robotic picking systems.
If you’ve ever wondered how warehouse automation could benefit your business, our blog will guide you through the different types of warehouse automation available.
What is warehouse automation?
The benefits of warehouse automation are clear. Install the correct system for your stock profile, processes and warehouse space and it can maximise your supply chain to give you an operational advantage over your competitors. As technology and automation develop, warehouse owners are increasingly finding these intuitive systems are maximising processes across the whole warehouse.
Advantages of automation in the warehouse
One of the key advantages of implementing warehouse automation is the significant cost savings it can provide. Incorrect picking errors can be expensive. However, implementing consistent control and accuracy during repetitive tasks, while simultaneously increasing the throughput of stock can accelerate how long it takes for orders to move through the warehouse. Get it right and you can reduce downtime, improve picking accuracy and therefore increase customer satisfaction by delivering orders on time.
However, you should not ignore how warehouse automation can increase the safety of your warehouse. Warehouse automation can efficiently utilise and zone your space to create safe working areas for your employees which reduces risks from moving vehicles and falls from height.
Challenges of warehouse automation
Of course, implementing automation into the warehouse isn’t a simple process and there are a few things you will need to consider. It typically requires a significant initial investment and you may need to consider whether the initial investment provides enough benefit to your business. Pick the wrong one and it could end up an expensive error. You also need to factor in additional costs associated with increased maintenance requirements.
Successful automation relies on careful planning. First, you need to assess how you will seamlessly switch current warehouse processes towards automation without facing significant periods of downtime. You will need to allocate realistic timeframes and resources. Finally, once in place your employees will need time to adjust to a new working approach and you will need to allow time for additional staff training.
There is one other big consideration and that’s available warehouse space. Automated systems have different special requirements. For example, automated robots can move more freely and help you maximise available space whereas a conveyor belt needs a fixed area which could eat into available storage capacity.
Types of warehouse automation
There is a wide range of warehouse automation solutions available and there is no one-size-fits-all solution. Typically, you will find your warehouse requires multiple layers of automation to deliver the best results.
Automation falls into four main categories; basic automation is seen as the entry-level point, system automation uses software-based solutions to improve stock location and mechanised automation uses autonomous robots to retrieve and transport items. The final group are advanced systems which combine the advantages of other automation solutions and enhance them with artificial intelligence and robotics.
Basic Automation
This is the type of automation you will find in most warehouses. The simplicity of it makes it incredibly adaptable so that it can seamlessly fit into most environments.
Systems include:
- Conveyors form the backbone of most warehouse automation systems. They are favoured for their ability to maintain maximised throughput volumes, continuous operations flow and the ability to efficiently link between different operational zones. There is a wide range of options from simple gravity-powered rollers, and spiral conveyors for transporting stock between levels, right through to a sophisticated belt warehouse system.
- Barcode Scanners ensure you have real-time visibility of stock movement and location to improve accuracy. These systems include everything from handheld scanners for manual warehouse operations, to fixed-mount scanners for conveyor systems right through to mobile terminals combining scanning and data processing.
- Radio-Frequency Identification (RFID) takes barcode scanning a step further by enabling contactless identification of stock using tags that contain unique identifiers. Readers automatically detect and read the tag and can read multiple items simultaneously. They also don’t require visible sight of the tags and can even read a tag through packaging materials.
System Automation
System Automation helps you to keep track of where goods are stored within your warehouse. They typically involve software-based warehouse systems that make it easier for operators to coordinate orders and locate stock.
Systems include:
- Warehouse Management System (WMS) solutions have significantly evolved since their early days, developing into platforms that optimise multiple warehouse operations. WMS can cover everything from real-time inventory management and tracking, order processing, planning of labour, task management and reporting.
- Warehouse Control Systems (WCS) act as an intermediary between management systems and warehouse automation. These solutions can coordinate and control real-time operation of conveyors, sorters and automated systems. They are ideal when looking to maximise throughput volumes and minimise bottlenecks.
- Warehouse Execution Systems (WES) bridge the gap between the management of the warehouse with WMS and automation coordination with WCS. WES systems help you to optimise tasks, enable real-time resource allocation, balance workloads, monitor performance and automate decision-making. The rise in this system demonstrates the complexity of running a modern warehouse.
Mechanised Automation
In its simplest form, mechanised automation involves delivering the correct product to the right area within the warehouse using control software and physical systems. However, these solutions can easily be designed into complex systems that meet a number of your warehouse requirements.
Systems include:
- Automated Storage and Retrieval Systems (ASRS) consist of computer-controlled solutions that replace manual picking and loading of stock. ASRS uses autonomous shuttles which operate on rails within storage aisles. They are ideal for warehouses that hold high load volume and require high storage density but face space constraints or require picking accuracy. After the stock is picked, items can be moved to a conveyor and carried to their packing or shipping destination.
- Automated Guided Vehicles (AGVs) pick stock and transport it across the warehouse without the need for human intervention. They require a dedicated space to operate and are limited by travelling down set paths. Movement is typically driven by magnetic guidance using warehouse floor strips or markers, wire guidance or laser navigation using reflectors. They are ideal for handling substantial loads and repetitive stock movement or large and straightforward warehouse setups
- Autonomous Mobile Robots (AMR) are a more intelligent version of AGV making it suitable for smaller warehouses or complex setups. They use sensors and artificial intelligence to navigate independently which removes the need for a fixed guidance system. These robots create and update their own paths and can adapt in real-time to their surroundings.
How to automate your warehouse
When looking to add automation to your warehouse, the starting point is to know your organisation's requirements, resources, and limitations. Success relies on following a structured methodology, from initial assessment through to operational deployment.
Things to consider include:
- What are the upfront costs of your automation solution and when will you achieve Return on Investment (ROI)? Check this during the planning stage.
- Choose your supplier carefully. You may have an idea in your mind about the type of automation that you require, but an experienced supplier will help you choose the best system for your business while also recommending other automation systems that might provide additional operational benefits.
- Will the system meet demand level, turnover, stock type, stored SKUs and their particular attributes?
- Does your warehouse have the capacity to accommodate the equipment?
- What training do you need to provide for your team to ensure they can work effectively and safely with the new equipment?
- Does the automation work with existing equipment and the racking within your warehouse? Will you need to consider new equipment or modifications to your racking to ensure everything works seamlessly?
- Has your supplier designed a modular system that you can reconfigure when your business needs change?
- Have you considered the impact of maintenance requirements and potential downtime?
If you’d like to find out more about the wider benefits of installing an advanced warehouse automation solution, get in touch and we can answer all your questions.
