Warehouse automation is the process by which automated technologies and systems are used to optimize efficiency, reduce costs and improve safety and customer service in a warehouse.
These automated systems may include robots, autonomous vehicles, automated storage systems (AS/RS), inventory control systems, sorting systems, among others.
What is the process of automating a warehouse?
The process of automating a warehouse can vary depending on the degree of automation desired and the size and complexity of the warehouse.
Needs analysis
First, a detailed analysis of the warehouse needs is carried out at to determine the degree of automation required and to select the appropriate technologies and systems.
For example, a small warehouse may benefit from automation at a low level, while a larger warehouse may require a more advanced level, such as the use of robots or AS/RS systems.
2. Design of the automated solution
Once the needs have been analyzed, the automated solution for the warehouse is designed, taking into account space constraints, budget, efficiency and safety.
3. Implementation and start-up
The implementation and commissioning of the automated system is also a customized process, as it will take into account the existing warehouse infrastructure and available resources, including warehouse personnel, who must be trained in the use of automated technology to ensure a smooth transition and efficient use.
This is where suppliers like Rielec can help you not only in the implementation of technological solutions, but also in the monitoring and training of your operators.
4. Monitoring and adjustments
Finally, it is important to monitor and make adjustments to the automated system based on changing warehouse needs and market trends to ensure that it remains efficient and useful.
Advantages of warehouse automation
As we have already mentioned, warehouse automation offers several advantages, especially those focused on productivity and safety. These can be summarized as follows:
- Increased efficiency: Automated systems can perform tasks faster and more accurately than humans, reducing cycle times and improving the efficiency of the warehouse operation.
- Cost reduction: Warehouse automation can help reduce labor costs through labor efficiency by allowing operators to focus on performing their tasks in areas of reduced distance, thus concentrating productivity. It can also help reduce warehousing costs by optimizing the use of space and avoiding unnecessary inventory build-up.
- Improved safety: The need for human workers to perform dangerous tasks is reduced.
- Improved accuracy and traceability: the technology used in warehouse automation allows for greater accuracy in inventory tracking and recording, which helps prevent errors and losses, and improves product traceability.
- Increased flexibility: Automated systems are able to adapt to changes in order volumes and fluctuations in demand, allowing companies to be more flexible and responsive to market changes.
- Improved customer service: with automation, orders can be processed faster and more accurately, enabling companies to deliver products to their customers in less time, improving customer satisfaction and loyalty.
Types of warehouses according to the degree of automation
There are various degrees of automation in a warehouse, from fully manual to fully automated systems. Below, we describe some of the most common degrees of automation in a warehouse:
- Manual warehouses: All tasks are performed by humans, from receiving goods to order picking and product storage.
- Semi-automated warehouses: Some tasks are automated, such as the use of forklifts and automated storage systems (AS/RS) to move products within the warehouse. However, packing and order picking tasks are still performed by humans.
- Highly automated warehouses: Most tasks are automated, including goods receiving, product storage, order picking and product packaging. Robots and autonomous vehicles are commonly used here.
- Fully automated warehouses: In this type of warehouse all tasks are automated, including goods receiving, product storage, order picking and product packing. Robots and autonomous vehicles are used to move products within the warehouse, while artificial intelligence systems are used to plan and optimize the warehouse operation.
Where there is automation, especially in the last two points, we could talk about retrofit logistics solutions; those in which the warehouse is upgraded, either to better optimize space or to increase the use of robots in it.
Types of warehouse automation
There are several automated technologies that can help optimize productivity in a warehouse. It is also important to mention that not all of these technologies are necessary and that the choice will depend on the specific needs and requirements of each company.
Types of warehouse automation in the handling of goods in crates
The vast majority of warehouses need to move and handle goods wrapped in boxes, so the automated technologies that can be used in this case will be similar to any other type of warehouse automation. However, since the needs between two cases can be so different, the final solutions can vary completely.
We summarize the most common automated technologies and systems:
- Robots: Robots are used to perform a variety of tasks in a warehouse, such as picking, packing, sorting and order picking. Robots are capable of working quickly and accurately, and can perform tasks that would be difficult or dangerous for humans.
- Autonomous vehicles: These vehicles are used to move products within the warehouse, and are able to navigate autonomously in a pre-established environment. They can transport products and make direct deliveries to workstations.
- Automatic Storage Systems (AS/RS): These systems are used to store and retrieve products automatically. They can be mechanical or robotic and allow for greater storage efficiency, as products are placed and retrieved automatically.
- Inventory control systems: Use technologies such as barcodes, RFID or sensors to automatically monitor inventory and keep an accurate record of products.
- Sorting systems: Use technologies such as imaging, sensors and machine learning to sort and separate products automatically. They help optimize sorting time and improve accuracy.
- Automatic packaging and labeling systems: Robots and mechanical devices to automatically pack and label products, which helps increase process efficiency and accuracy.
- Order picking systems: In this case, technologies such as robots and mechanical devices automatically pick the products needed for a specific order, helping to increase the efficiency and accuracy of order picking.
- Automated conveyor systems: These systems use robots and carts to transport boxes through the warehouse. They can be both guided and unguided, and allow for greater efficiency in moving the boxes.
- Automatic scanning systems: Scanners and barcodes or RFID to automate the process of scanning and registering cases. This helps reduce errors and increase accuracy in case tracking.
Types of warehouse automation: goods receiving and dispatch areas
Receiving and picking are two critical areas in a warehouse, and are especially important when implementing automated technology.
In the goods receiving area, automated technologies can be used to process and record incoming goods. Having read this far, we know that we can implement barcode or RFID readers to scan products and automatically record essential information such as item number, quantity, price, expiration date, among others.
In addition, autonomous vehicles or robots could be used to move products from delivery trucks to the storage area.
In the outbound goods area, automated technologies can be used to prepare and pack orders, with other robots automatically picking the products needed for a specific order. On the other hand, automated packaging systems could be used to pack products quickly and accurately.
Types of warehouse automation according to conveyor systems
Warehouse automation can also be classified according to the conveyor system used, some of which are as follows:
- Manual conveying systems: Boxes are moved by hand by workers, using carts and other manual equipment. This system is suitable for small warehouses or where storage volumes are low.
- Mechanized transport systems: Boxes are moved by mechanized machinery, such as forklifts or forklifts. This system is suitable for larger warehouses or where storage volumes are high.
- Automated conveyor systems: Boxes are moved by robots and automated carts, as well as conveyor belts guided by an automatic control system. This system is suitable for large warehouses or where storage volumes are very high and greater accuracy in the movement of boxes is required.
- AGV (Automated Guided Vehicle) conveyor systems: a specific type of automated conveyor, these vehicles move automatically following a guide, such as conveyor belts, lights, floor markings or other means. This system is suitable for large warehouses or where storage volumes are very high and greater precision is required in moving boxes and transporting them over long distances.
Each of these systems has its own advantages and disadvantages, and the choice will depend on the size, storage volume and accuracy required in the warehouse.
Types of warehouse automation: picking or order picking systems
Implementing automated technologies in order picking (also known as "picking") is an effective way to improve efficiency and accuracy in warehouses. Examples include:
- Automatic picking systems: These systems use robots and mechanical devices to automatically pick the products needed for a specific order. It helps to increase speed and accuracy in order picking.
- Machine vision order picking systems: Automatically identify and locate the products needed for a specific order. This helps improve order picking accuracy and efficiency.
- Automatic worker guidance systems: Through devices such as tablets or screens, they automatically guide the worker through the necessary steps for the preparation of a specific order. This helps improve accuracy and efficiency in order picking.
- Automated sorting systems: These are used to sort products automatically, helping workers to quickly locate the products needed for an order.
- Automated tracking systems: These systems use technologies such as RFID or barcodes to automatically track products through the picking process, helping to ensure that orders are prepared correctly and shipped in a timely manner.
Types of warehouse automation: packaging systems
Another common area of operation is packaging, so we could distinguish different ways of automating a warehouse according to this:
- Manual packaging systems: Everything is done by hand.
- Mechanized packing systems: In this system, boxes are packed by mechanized machinery, such as bag sealers or stretch wrapping machines. It can work in larger warehouses or where storage volumes are high.
- Automated packing systems: Boxes are packed by robots and automated carts, guided by an automatic control system. Suitable for large warehouses or where storage volumes are very high and greater precision in the packing process is required.
- Customized packaging systems: depending on the specific needs of the product, automation will be carried out, especially in cases where the products are fragile or have special dimensions.
Automation of a warehouse as a customized process
As we have seen, warehouse automation is a highly customized process, as the needs and requirements of each warehouse are unique. It is important to consider the specific characteristics of the warehouse, such as size, product flow, available space, and safety and compliance requirements, when planning automation.
From Rielec we help you to automate your logistics processes with a turnkey project, thanks to a set of solutions and automated systems, from its implementation to the monitoring and training of your staff.
