Levels, Types and Applications of Warehouse Automation

Warehouse Automation: Levels, Types and Applications

Introduction

This article will take an in-depth look at warehouse automation.

The article will provide more detail on topics such as:

Principles of Warehouse Automation
Levels and Drivers of Warehouse Automation
Types of Warehouse Automation
Why and How to Automate a Warehouse
Contemporary Warehouse Automation and Robotics
Applications and Benefits of Warehouse Automation
And Much More��

Chapter 1: Understanding How Warehouse Automation Principles Operate

This section delves into the essence of warehouse automation and its operational dynamics.

Defining Warehouse Automation

Warehouse automation is the process of substituting labor-intensive, repetitive duties with automated systems. This shift prioritizes freeing up workers to focus on essential tasks, like quality control, instead.

The integration of material handling and warehouse automation involves software that executes simple tasks requiring minimal human input. Bulk material handling automation equipment is capable of conveying, loading, unloading, weighing, processing, and feeding various bulk solids. These systems act much like robots in manufacturing, enhancing the efficiency of materials handling.

Exploring Digital Automation

Digital automation through robotics mitigates manual operations by utilizing data, software, and automatic data capture technology like mobile barcoding. Key advantages include its smooth alignment with ERP systems, improved safety, boosted security, and more adept data handling. By reducing human error and manual tasks, digital robotics boost efficiency in material handling, uplift customer service, enhance employee morale, and cut costs related to human mistakes. Technologies like mobile barcode scanning and RFID bolster these positive impacts further.

Adopting digital automation systems entails initial expenses, covering deployment, employee training, necessary hardware, software, and maintenance agreements. However, there are risks of data loss, potential damage, and heightened cybersecurity concerns.

Understanding Warehouse Physical Automation

Physical automation technology reduces the time spent by staff moving around the warehouse, leading to more efficient workflow setups. Robotics enhance both the warehouse's capacity and efficiency, fortifying service reliability and scalability. Nevertheless, it comes with high upfront costs, a lack of skilled operators, and costly maintenance for equipment often designed for specialized applications.

For organizations to leverage automated warehouse systems effectively, careful planning and strategic organization are essential. Such systems are particularly beneficial for large-volume warehouses and distribution centers that can accommodate specialized automation equipment.

Mechanics of Warehouse Automation

Warehouse automation is broadly classified into physical and digital categories. Digital automation harnesses electronics and software to reduce manual work and streamline vendor and customer management. Digital automation examples include warehouse management systems and automatic identification and data capture (AIDC) technologies.

In practice, digital automation enhances security features, reduces risks—both legal and operational—and provides more efficient enterprise resource planning alongside improved safety. Though it decreases human errors and the need for manual work, implementing digital robotics involves substantial initial investments, including support contracts and training for staff, as well as system setup costs.

In contrast, physical automation lessens the labor demand on employees through advanced warehouse equipment. Examples encompass automated guided vehicles, manufacturing robots, and robotic systems integration, facilitating the transport of goods with minimal employee effort, thus boosting efficiency and storage capacity.

Physical automation with robotics also lends scalability, enhances reliability, and boosts performance levels. Yet challenges include a limited skilled workforce to operate and handle the technology, large initial financial outlays, and elevated maintenance expenses.

Chapter 2: What are the levels and drivers of warehouse automation?

This chapter explores the different levels of warehouse automation and the primary drivers behind its adoption in modern supply chain management and intralogistics environments.

Levels of Warehouse Automation

The evolution of warehouse automation can be segmented into multiple levels, each defined by the degree to which technology streamlines warehouse operations.

Low Automation

Low automation in a warehouse or factory is characterized by manual processes that heavily rely on human personnel. Warehouse workers are responsible for physically moving inventory, data collection, operating equipment, and constructing products. While low-automation facilities may feature some basic automated tools—such as barcode scanners or conveyor belts—they often suffer from inconsistent productivity, higher risk of human error, limited working hours, elevated labor costs, high worker turnover, defective parts, and unexpected production stoppages. In environments with limited automation, supply chain optimization is challenging, leading many companies to explore advanced material handling equipment and automation solutions.

Automation with Robotics Warehouse Management Systems

Implementing a warehouse management system (WMS) combined with robotics transforms traditional processes. A WMS is a comprehensive software platform that manages warehouse operations and logistics flows, optimizing inventory tracking, inventory control, and storage location assignment. The integration of robotics with a WMS—such as Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs)—allows for seamless movement of goods, improved picking accuracy, and streamlined replenishment processes. From goods receipt to order fulfillment, robotics-powered WMS maximizes warehouse efficiency, space utilization, and real-time data access, while reducing labor costs and minimizing product handling errors. This level of automation is crucial for e-commerce fulfillment centers, third-party logistics providers, and manufacturers seeking scalable solutions.

Advanced Automation

Advanced warehouse automation leverages sophisticated technology such as industrial robots, collaborative robots (cobots), automated storage and retrieval systems (AS/RS), and conveyor automation to manage complex operations. With programmable automation protocols executed throughout the work cycle, these systems handle everything from picking and sorting to packaging and shipping. Advanced automation is often enabled by machine learning, artificial intelligence (AI), and warehouse execution systems (WES) that orchestrate the movement of products across the facility. The result is higher throughput, faster order processing, improved inventory accuracy, increased safety, and significant cost reductions. This level of automation is especially prevalent in high-volume distribution centers, omnichannel warehouses, and manufacturers with just-in-time logistics requirements.

Drivers of Warehouse Automation

Modern business demands, rising labor costs, changing consumer expectations, and the need for operational efficiency are prompting companies to adopt warehouse automation solutions. Automated storage and retrieval systems (AS/RS), coupled with advanced inventory management, not only boost receiving, storage, and distribution productivity but also minimize warehousing costs, enhance workplace safety, and support supply chain resilience in dynamic markets.

Key automated warehousing technologies and trends currently impacting the industry include:

Picking Automation

Order fulfillment and picking remain some of the most labor-intensive warehouse activities, with direct impacts on delivery speed and accuracy. Traditionally, staff members manually locate and retrieve required SKUs, using carts or other manual material handling equipment, before packaging and shipping orders. Automated order picking systems—such as Goods-to-Person (GTP) solutions, automated picking robots, and robotic shuttle systems—transform this process by reducing travel time, boosting picking accuracy, and speeding up order assembly. By leveraging picking automation and robotics integration, warehouses can maximize throughput, reduce errors, and meet rising e-commerce demands for rapid order fulfillment. Mini-load AS/RS systems and carton flow systems are particularly effective for operations with high SKU counts and frequent order turnover.

Automated material handling systems, such as conveyors and robotic arms, perform pick and place operations, precisely moving products between storage, sorting, and shipping areas. Integrated warehouse automation systems not only accelerate product movement but also provide real-time inventory monitoring and quality management, crucial for ensuring order accuracy and customer satisfaction.

Intelligent Internal Transportation

The repetitive nature of transferring goods within warehouses and distribution centers requires substantial labor resources. By streamlining transportation activities and adopting automated guided vehicles (AGVs), autonomous mobile robots (AMRs), and overhead conveyor systems, companies can significantly reduce manual handling and improve operational flow. These automated transportation solutions enable warehouses to reassign workers to higher-value tasks such as process improvement and exception management.

Popular internal transportation technologies include roller conveyors for cases and totes, and pallet conveyor systems for bulk movement. Automated guided vehicles and AMRs efficiently navigate warehouse aisles, transport products between storage and production zones, and enhance material flow without the need for human intervention. These automation strategies are key for facilities aiming to optimize space, reduce transit times, and maintain consistent throughput.

Dark Warehouses

Dark warehouses represent the pinnacle of full-scale warehouse automation, operating without the need for human intervention or lighting. These highly automated distribution centers utilize a combination of robotics, AS/RS, conveyor networks, and advanced control software to achieve 24/7 operation and maximum throughput. As businesses pursue supply chain digitalization and resilience, dark warehouses offer advantages such as lower energy consumption, reduced labor requirements, improved resource utilization, and enhanced security.

Additionally, dark warehouse automation supports sustainable supply chain initiatives by optimizing energy use (since lighting is unnecessary), reducing carbon footprints, and minimizing errors that lead to waste. Companies deploying these solutions achieve greater control over inventory, increased productivity, and improved order accuracy—all critical for industries like automotive, pharmaceuticals, and retail facing increasing competition and demand volatility.

Systems for Loading and Unloading Trucks Automatically

Truck loading and unloading are among the most time-sensitive and labor-intensive logistics activities. Automated truck loading and unloading systems—such as telescopic conveyors, robotic palletizers, and automated dock equipment—drastically reduce loading cycle times and limit manual material handling. These conveyor-based and robotic solutions streamline inbound/outbound freight operations, minimize damage, lower labor costs, and improve dock safety.

Often integrated at docking stations, these automated systems rapidly transfer cargo between trucks and the warehouse, supporting higher shipping volumes and more efficient cross-docking operations. This technology is crucial for companies seeking to scale their distribution capacity, reduce lead times, and improve overall warehouse productivity in competitive markets.

Software as a Service (SaaS) Warehouse Management

Cloud-based SaaS warehouse management systems are transforming logistics by delivering scalable, flexible, and real-time inventory control tools accessible from anywhere. Companies seeking precise control over inventory operations, order tracking, and supply chain visibility increasingly digitize their facilities with advanced WMS software. SaaS WMS platforms allow for rapid deployment, reduced IT overhead, and seamless integration with other enterprise resource planning (ERP) and supply chain management (SCM) systems.

For growing businesses and omnichannel retailers, adopting a cloud-based WMS simplifies automation integration, supports multi-location operations, and empowers data-driven decision-making. According to Grand View Research, the shift toward SaaS WMS is accelerating due to its cost-effectiveness, scalability, security, and ability to provide advanced analytics for inventory and labor optimization.

Big Data Analysis in the Modern Era

One of the core advantages of warehouse automation is the ability to collect, manage, and analyze large volumes of data—commonly referred to as “big data”—within logistics and supply chain operations. Automated warehouses generate detailed data sets on inventory movement, order cycles, equipment utilization, and workforce efficiency. Leveraging data analytics, artificial intelligence, and machine learning algorithms, companies can conduct predictive analytics, demand forecasting, and process optimization.

Big data is integral to the performance of Automated Storage and Retrieval Systems (AS/RS), supporting enhanced equipment scheduling, route optimization, and real-time KPI monitoring. Access to actionable insights—such as sales trends, SKU velocity, and equipment uptime—enables supply chain managers to proactively address bottlenecks, balance inventory levels, and improve service levels. As the logistics industry adopts Internet of Things (IoT) sensors and connected devices, the ability to harness big data is essential for future-ready warehouse operations and sustainable logistics growth.

Who are the leading manufacturers and suppliers?

How to Choose a Warehouse Automation System for Your Business

When evaluating warehouse automation technologies for your facility, consider factors such as operational complexity, picking volume, SKU diversity, and integration with existing systems. Leading solutions include modular conveyor systems, scalable robotic picking platforms, and cloud-based WMS software. Consult with experienced automation integrators to assess your warehouse’s unique needs and to identify options that support business growth, operational agility, and future scalability. Don’t forget to analyze the return on investment (ROI), implementation timelines, and compatibility with technologies such as RFID, IoT, and machine learning. By taking a strategic approach to automation adoption, you can transform warehouse productivity, boost customer satisfaction, and gain a sustained competitive edge in an evolving supply chain landscape.

Chapter 3: What are the types of warehouse automation?

The various types of warehouse automation include:

Goods-to-Person

Goods-to-person is the most commonly used method for reducing congestion and maximizing efficiency. This approach includes carousels, conveyors, and vertical lift systems. When implemented effectively, these systems can significantly enhance the speed of warehouse picking.

Lightweight products are stored within the system and automatically transported to the operator for picking. This reduces walk time and provides accurate pick and inventory data.

Goods-to-person systems can be seamlessly integrated with picking technologies such as AI-powered robotics, offering fully automated solutions for piece picking. These systems are also highly scalable, making them adaptable to a company’s growing demand.

The workstation screens display the exact item required by the operator, significantly minimizing order errors that are often a challenge in high-demand and high-speed environments.

Goods-to-person procedures offer numerous benefits and are often chosen for their efficient use of space, dynamic functionality, seamless integration with other technologies, and reduction of order errors.

Additional advantages of goods-to-person systems include the integration with warehouse software, storage consolidation, improved space utilization, and increased operational uptime. Key factors to consider when implementing goods-to-person technologies include peak season requirements, facility layout and space, automation system integration and technology, floor slab integrity, production rates, and the future objectives of the business.

Automated Guided Vehicles (AGVs)

These are also known as mobile robots. Unlike robotic arms, which consist of joints and links attached to a base, mobile robots are not confined to a fixed range of movement. They are self-contained and can navigate along surfaces, spaces, or lines. Often, mobile robots are combined with robotic arms, providing a platform for the arms to perform versatile functions such as scanning, remote handling, and probing.

The design of automated guided vehicles is very complex as compared to that of robotic arms. Besides the issues of locomotion, there are many other aspects to consider such as path planning, perception, localization, and motion control. Automated guided vehicles are classified into the following categories.

Autonomous AGVs

This robust, flexible, and accurate automation solution is designed to meet the needs of producers and operators of automated guided vehicles. Its advantages include flexibility and scalability.

Forklift AGVs

These are automated guided vehicle navigation systems integrated into forklifts. They are primarily used for stacking pallets at various heights and are well-suited for ground-level pallet lifting.

Automatic guided vehicles (AGVs) are load carriers that navigate a facility’s floor autonomously, without a driver or operator onboard. These computer-controlled, wheel-based systems use both software-based and sensor-based guidance systems to control their movement. AGVs ensure safe load transportation by following predetermined routes, accelerating and decelerating accurately, and using bumpers to automatically detect obstacles. They are commonly used for transporting raw materials, work-in-progress, and finished items in robotics manufacturing production lines, as well as for storage and retrieval to support picking in distribution and warehousing applications.

Underride AGVs

These are also known as automated guided carts. They operate by driving underneath a basket and slightly lifting it, performing their tasks at the destination without any intervention. Primarily used in hospitals, they are employed for delivering medical supplies, food, and linens.

Towing AGVs

These are also known as tagger-guided vehicles. They are used to pull undriven trailers or carriers and can handle multiple loads more efficiently compared to underride AGVs and forklift AGVs, as they do not need to perform additional lifting. However, towing automated guided vehicles are designed exclusively for transport and cannot position the loads at their designated locations.

Unit Load AGVs

These automated vehicles are designed for transporting palletized or unitized goods without lifting the load from the ground. Lifting is handled by other equipment, such as forklifts, conveyors, and cranes.

Assembly AGVs

These are also known as tunneling automated guided vehicles. Their primary use is transporting goods to an assembly point. They are highly maneuverable, making navigation straightforward as they can easily orient themselves and fit into assembly stations.

Heavy Load AGVs

These are commonly used in steel and paper mills, where finished rolls of products are transferred for distribution or storage. They are equipped with enhanced safety features compared to other types of automated guided vehicles and have a very robust construction to handle the demanding environment.

Mini AGVs

These are also known as small load carriers. Mini automated guided vehicles are designed to transport small parts and typically operate in fleets or swarms. They offer great flexibility, high-speed movement, and are equipped with systems that ensure stability and a minimal turning radius. They are commonly used in selective racking systems.

Autonomous Mobile Robots (AMRs)

Autonomous mobile robots are designed to move automatically without a pilot on board. Equipped with sensors, they can perform various tasks by understanding and interpreting their environment. The primary purpose of using autonomous mobile robots is to reduce repetitive actions, such as moving pallets from one location to another, allowing operators to focus on tasks that require more attention.

AMRs and automated guided vehicles (AGVs) share many similarities but also have key differences. The most significant distinction is flexibility. Unlike AGVs, which follow rigid, predetermined routes, AMRs can choose the most effective path for each task. Additionally, autonomous mobile robots are designed to work collaboratively with humans during picking and sorting activities, offering greater adaptability and integration in dynamic environments.

The use of autonomous mobile robots offers several advantages, including:

Increased efficiency and productivity - They keep the operators on task and they set the pace for associates.
Reduced labor �� Autonomous mobile robots minimize the amount of work that is involved with the handling of materials by having efficient navigation systems.
Less human error �� Since workers are led through each of the tasks being carried out, losses are greatly reduced and there is better accuracy when handling materials.
Better scalability - Initially, only a few units need to be employed; additional units can be added later as operational needs change.

Another advantage of using autonomous mobile robots is that there is improved safety. This is because they have built-in cameras and sensors which help them to define and interpret their environment and avoid collisions.

Robotic Arms

Robotic arms utilize machine learning to enhance distribution and boost productivity. Advances in technology are leading to the introduction of automated picking systems in labor-constrained warehouses. As technology progresses and logistics operators facing labor shortages seek to automate to meet increasing demand, the use of robots capable of picking individual items is rising. Software-controlled robotic arms are being employed by businesses to sort apparel and e-commerce packages, pack industrial supplies and bread, and, in some cases, select electronics and consumer goods from larger bins to prepare orders for delivery.

Experts suggest that technology won't soon replace human jobs entirely. However, recent developments show that warehouse robots are evolving as advancements in computer vision and software enhance their capabilities, allowing them to take on more tasks traditionally performed by humans.

For example, at IMTS 2022, KUKA Robotics introduced "Sensitive Cobotics," highlighting the future of automation with their new LBR iisy cobot. The LBR iisy is designed for rapid and seamless integration into any system as a ready-to-use automation solution. It is versatile in robotics manufacturing applications, ranging from controlled, pre-determined production processes to open, unstructured work environments with varying conditions. Collaborative robotic devices like the LBR iisy can be quickly and effectively incorporated into any robotics manufacturing application.

Robotic Palletizers

In accordance with pallet configuration, a robotic palletizer may handle one or more units at once and arrange the items in a variety of layers on a pallet after taking them off a conveyor. Different pallet designs and product varieties may be easily accommodated by robotic palletizing technologies.

Additionally, palletizing and depalletizing robots can be trained to handle multiple SKU infeeds on a single line. Utilizing data from vision systems, these robots can select and position different SKUs onto various pallets. Depending on the stacking patterns and requirements, a single robot picking one product at a time can palletize at rates ranging from 8 to 30 cases per minute. When picking rows of products or entire layers, the rate can increase even further.

Cartesian Gantry Robots

While SCARA and articulating arm robots are among the most well-known types of robots on the market today, gantry manufacturing robots are increasingly recognized for their efficiency in completing large tasks within a small area. Also known as Cartesian robots, gantry robots are used in automation assembly and production lines. Though they have historically been underestimated, their straightforward construction, low cost, scalability, and various motors and control software options are changing this perception.

Gantry robots can utilize up to 96% of the space and volume within a cubic work environment. They are often mounted on an X or X/Y axis beam supported by a solid framework, similar to their larger, more famous counterpart, the gantry crane. The X, Y, and Z axes define coordinates in three-dimensional space, allowing for three degrees of freedom due to the perpendicular arrangement of each axis. Gantries are further characterized by their additional support members at one or both ends. Unlike arm-style robots, gantry robots can be scaled to large sizes in all three dimensions. They are particularly effective for tasks requiring minimal additional orientation or when items can be pre-arranged before the robot engages them.

The advantages of using a Cartesian gantry robot include:

They can operate with virtually any length movement on three or more axes.
They are scalable.
The size of the gearbox and motor can be determined by their speeds and range of motion.
They are suitable for hanging mild, to heavy, loads.
They are flexible and effective owing to the scalability of linear axes.
They are inexpensive.

The disadvantages of using a Cartesian gantry robot include:

They cannot be adjusted to reach into, or around, obstacles.
Their vertical slides, belts, and rails are difficult to weatherproof.
They cannot stand alone and need stands, frames, or other mountings.

Automated Storage Retrieval Systems

These systems manage the retrieval and storage of cargo in designated locations within a warehouse. Designed to automatically handle materials, they eliminate the need for employees or operators to perform these tasks. Automated retrieval systems come in various configurations depending on the warehouse's operational requirements, including vertical lift modules, carousels, shuttles, or cranes. The benefits of automated storage retrieval systems are as follows:

Lower costs of labor - Automated retrieval systems take manual labor out of placing and picking operations so there is only a minimal need for human labor.
Increased picking accuracy –The degree of accuracy is increased by the removal of the error-prone manual picking processes.

Pick-to-Light and Put-to-Light Systems

With a pick-to-light system, an employee first scans a barcode to access the specific order details associated with it. Workers are then guided to the storage locations using light-based devices. The lights on the racks indicate the products that need to be picked to fulfill the order.

Pick-to-Light and Put-to-Light Systems

With a pick-to-light system, an employee first scans a barcode to access the specific order details. Workers are then guided to the storage locations using light-based devices. The lights on the racks indicate the products that need to be picked to fulfill the order.

Pick-to-light and put-to-light systems operate as opposites of each other. In a pick-to-light system, workers scan a barcode as the first step, and the lights mounted on the rack indicate where the material is to be selected from in storage. In a put-to-light system, lights guide workers on where to place items. These systems offer significant advantages, including increased productivity, estimated to improve by about thirty to fifty percent with pick-to-light systems. They also enhance picking accuracy, as workers are less likely to make mistakes since they no longer need to manually determine item locations. Additionally, training costs are reduced due to the intuitive and straightforward nature of these systems, with training often taking as little as 30 minutes.

Voice Picking and Tasking

This method involves using verbal commands to assist factory employees in fulfilling their orders and duties. Typically, voice picking and tasking systems are integrated with enterprise resource planning (ERP) software or warehouse management systems (WMS). When an order is received, the voice picking and tasking system automatically determines the requirements of the order.

Afterward, the system verbally communicates the instructions to employees through a headset. Employees are directed to the precise location of the item to be picked and informed of the required quantity. They can also interact with the system to confirm locations and quantities. Voice picking and tasking systems offer several benefits, including:

Improved safety �� There is less distraction as opposed to other picking devices. Since it is hands-free, workers are less likely to be prone to accidents.
Improved picking accuracy - Most of the distractions associated with other picking processes are eliminated and there is an improvement in accuracy.
Better productivity �� Workers can concentrate on issues that are crucial, like picking, rather than having to stop to read paperwork for orders.

Automated Sortation Systems.

This method eliminates manual labor by automatically sorting materials on a conveyor system and directing them to designated locations within the warehouse. Automated sortation systems utilize various technologies, including sensors, barcodes, and scanners. They are generally categorized into two types: case sorters, which handle entire totes, and unit sorters, which manage individual items. Automated sortation systems offer several benefits, including:

Faster processing �� They can function much faster and longer as compared to humans. This improves efficiency, as well as productivity.
Less reliance on labor- Automated sortation systems are a great way to cope with small labor pools.
Better order accuracy �� Accuracy is increased by the reduction of human errors.

Collaborative Mobile Robots

Collaborative mobile robots are designed to work alongside human workers, aiming to reduce errors, enhance operating speeds and efficiency, and free up employees for other tasks. Their use has been shown to directly impact efficiency. These robots are employed in various operations, including palletizing, packing, inspecting, and picking.

Drones

Technically, drones are a type of robot that, while lacking advanced onboard computers, are utilized for inventory management. They scan barcodes to conduct warehouse counts, alert staff about products needing restocking, and identify misplaced goods. Additionally, some warehouse automation companies are exploring the use of drones for deliveries.

Chapter 4: Why should you automate a warehouse, and how can you do it?

This chapter will discuss the reasons to automate a warehouse and how to automate it.

Why Automate a Warehouse?

An inefficient warehouse can significantly impact customer experience. Automated warehouses, on the other hand, can handle more tasks with fewer resources and adapt well to increasing customer demands. Automation in warehouse operations offers numerous advantages, including reducing errors and enhancing overall efficiency.

Some frequently cited benefits of warehouse automation include reduced operational costs and labor, improved customer service, minimized human error, increased employee satisfaction, better resource utilization, and fewer shipping errors. Additionally, automation enhances order fulfillment through improved material handling and coordination.

How to Automate a Warehouse

Automating a warehouse requires a comprehensive project plan. Key elements to consider include identifying all stakeholders, conducting a risk assessment, creating a project schedule, and analyzing deliverables and goals. The process begins with forming a support team and appointing a project manager. This team will develop the project schedule, establish a timeline, and create a deliverables calendar. Additionally, implementation support plans are essential for successful execution.

Feedback from all management levels, including warehouse managers in various locations and corporate leadership, is crucial. Additionally, selecting the automation solution that best fits the business needs is essential. Thorough research and evaluation of different automation options are necessary. The process of warehouse automation can be broken down into the following steps:p>

Formation of an implementation team �� This team should consist of stakeholders with deep knowledge and experience regarding the current capabilities, challenges, and performance of the warehouse. The team must be adept at identifying technology gaps that need to be addressed. Additional experts with extensive experience in supply chain and demand automation relevant to warehouse operations can be included.

Collection of critical data �� Successful warehouse automation heavily relies on supply chain operations and critical business processes. Prior to implementing automation technology, it is essential to assess the current data infrastructure and collection procedures. This assessment ensures that ownership of data is assigned to skilled information technology stakeholders.

Evaluation of inventory controls �� Inventory control is central to warehouse operations. Standard operating procedures must be established before implementing the warehouse automation solution. These procedures should cover shipping, purchasing, receiving, inventory loss, and customer satisfaction. To measure the success of automated procedures and processes, key performance indicators (KPIs) must be defined.

Implementation of a warehouse management system �� The warehouse management system (WMS) software is designed to track and manage inventory, reduce labor costs, oversee warehouse operations, and enhance customer service. The chosen system should integrate seamlessly with existing software and support mobile devices.

Determining the best automation solution �� Choosing a warehouse automation solution is crucial. It must align with the company's specific goals and meet customer demand.

Best Practices in Warehouse Automation

Best practices for warehouse automation include:

WMS Integration

Make sure that the warehouse automation solutions you choose can integrate with a WMS platform. Look for solutions that automate inventory control, manage inventory, track and report labor costs, and connect dashboards. Familiarize yourself with WMS features and understand the differences between warehouse management and inventory management.

Scalable Solutions

Invest in scalable solutions, as technology should evolve with your company. The system should accommodate future expansions, including additional warehouses, personnel, tools, and supply chain partners such as third-party logistics providers or drop shippers.

Automate Data Collection

Begin with a system that automates data collection, transport, and storage, regardless of the type or extent of automation technologies you plan to explore. Combining cloud-based technologies with portable barcode scanners offers a low-cost, low-risk approach to automation. This setup allows you to collect essential warehouse performance and inventory data, store it in a consolidated cloud database for analysis, and reduce human error.

Carry Out Ongoing Cycle Counts

Cycle counts are an essential part of any warehouse management system, used to compare actual inventory levels with inventory data records. With automated data collection systems, you can use mobile barcode scanning or RFID sensors to perform continuous cycle counts. This data can then be reviewed for inconsistencies using dashboards.

Optimize Receiving

Since receiving is the starting point for warehouse data collection, it’s important to have a system that captures as much information as possible upfront to guide warehouse activities. Assess the dimensions, classifications, and packaging of incoming goods before establishing rules in the WMS for managing, storing, and allocating resources.

Examine Your Warehouse Design

For physical automation technologies like GTP and AS/RS systems, AGVs, and sortation systems to be effective, the warehouse must have a precise layout and ample space. Consider redesigning existing warehouses and distribution centers to better accommodate these technologies. Collaborate with solution providers, architects, and contractors who understand your specific needs. Ensure that this evaluation is included in your implementation budget.

Chapter 5: What are the top robotic integration companies?

With advancements in technology, companies now have access to a broader range of warehousing technologies than ever before. From logistics automation robotics and depalletizing robots to storage and order picking systems, these 21st-century automated solutions offer cost-effective methods for handling products and supporting assembly line automation and supply chain operations.

The market for robotics integrators and logistics automation is diverse, with many companies offering varying levels of technological skills and expertise. The effectiveness of these integrators often hinges on the design of their services, the type of software they use, and their control systems. While many companies may claim to have the tools for robotic integration, they might lack the necessary expertise. Customers seeking warehouse automation systems should thoroughly evaluate different providers and choose one with the expertise to meet their specific needs.

Formic

Formic aims to simplify and make robotics integration accessible, saving time, money, and labor costs. Their robotics systems offer a range of labor-saving logistics automation solutions, utilizing advanced robotics technology. Formic provides robotics for applications such as advanced manufacturing, consumer packaging, and other industrial uses, allowing companies to enhance their manufacturing capabilities with minimal risk.

Dematic

Dematic is a supplier of automated technologies and software for manufacturing, supply chain, and distribution centers. The company offers automated storage and retrieval systems for inventory management and utilizes advanced technologies in robotic mechatronics, guidance systems, and AI for automatic palletizing and depalletizing. Their fully robotic systems are designed to eliminate labor. Dematic serves companies of all sizes—small, medium, and large—providing robotic technology to enhance product flow and production efficiency.

Vanderlande

Vanderlande has extensive experience in warehouse logistics automation and automated material handling systems, offering a wide range of solutions for parcel center logistics. Their integrated solutions provide fast, reliable, and innovative technologies to help customers improve operational processes. Recently, Vanderlande has focused on e-commerce and has become a leading choice in logistics automation systems for this sector.

Knapp

Knapp is a leading provider of warehouse robot integration systems and logistics software. The company specializes in automation solutions for small item fulfillment, variability operations, and various AGV systems. Knapp's main goal is to deliver innovative robotic integration methods tailored to the specific needs of customers. With a highly trained team of experts and engineers, Knapp designs, implements, and refines warehouse solutions for a wide range of customers and operational conditions.

SSI Schaefer

SSI Schaefer aims to provide comprehensive, end-to-end automated systems for large-scale integrated warehouse automation. Their wide array of warehousing and supply chain solutions includes flat pack picking, single piece picking robotics, and AGV and AMR robot integration. The company offers automated solutions for picking, conveying, shipping, storage, and material handling, utilizing customized technologies and systems.

Chapter 6: What are contemporary warehouse automation and robotics?

Emerging technologies and robots have significantly improved businesses and their supply chains by enhancing the timeliness and accuracy of product information. Warehouse robotics primarily involves the implementation and ongoing use of automated systems. Historically, automation was used to reduce headcount, but now companies are struggling to maintain sufficient staff due to rising labor costs. Although industrial robots have been in use for many years, their capabilities and equipment were previously quite limited.

Emerging warehouse robots utilize artificial intelligence to navigate facilities effectively. They can work alongside humans to pick up or drop off items. Various types of warehouse robotics systems are employed, including facility management robots that can mow lawns or mop floors, autonomous drones that can access high shelves and deliver items, and static robotic systems designed for picking, pulling, dropping, and packing orders into boxes or containers. Robots play a crucial role in warehouses, performing a range of important tasks, which are listed below.

Sorting �� Sorting might appear straightforward for workers, but its automation involves a complex process. Automated robots in the warehouse are equipped with sensors, cameras, conveyors, arms, and software that enable them to identify specific items and direct them to the precise location for storage, retrieval, or disposal. Artificial intelligence sorting systems are integrated with these picking robots to accurately sort batch-picked items into their required order components.

Packaging �� Warehouse automation includes bagging machines and automated robots equipped with customization software to reduce packing time. These systems utilize length and weight dimensions to determine the optimal carton size for specific orders and guide associates through the correct packaging process.

Transportation - Carting items from one side of the factory to the other is often a significant task. Warehouse automation systems reduce the time workers spend on this chore, allowing them to focus on more critical tasks. Robotics, such as automated guided vehicles (AGVs), help reduce the stress and human labor associated with manual transportation. These robots can move order items from their designated zones to sorting areas. They serve various functions, including acting as conveyors to transport bins, boxes, and other items, or as monorails to move pallets and similar goods.

Replenishment �� Warehouse robots can enhance workflows by minimizing backorders and stockouts through automated reordering processes. They monitor inventory levels and issue notifications when stock drops below a predetermined threshold.

As a result, the following developments in robotics and automation are transforming the modern warehouse:

Robotics

In the first quarter of 2020, investments in warehouse robotics companies surged by 57%, exceeding $380 million. In a post-pandemic economy and in regions like Japan, where there is a shortage of workers, the adoption of warehouse robotics is expected to continue growing.

Cobotics

Cobotics refers to the collaboration between humans and robots, combining robotics with cooperative efforts. Cobots, designed to work alongside people, do not replace human workers. In warehouse automation, AMRs (Autonomous Mobile Robots) are a type of cobot that can scan their environment. With a 360-degree range of view, these cobot AMRs detect changes to avoid accidents with people and human-operated equipment, and can safely reverse when necessary.

Supply Chain as a Service

To address the need for flexible warehouse management and automated technologies such as autonomous robots, service-based warehouse marketplaces are growing. Companies offering subscription-based, fully automated warehouse solutions are challenging traditional producers and service providers of automated equipment and systems.

Drones

Intelligent drone fleets, powered by advanced algorithms and integrated with cloud-based warehouse management systems, can effectively manage inventories within warehouses. These drones often come equipped with vision sensors or barcode scanners to handle inventory management tasks and automate processes such as cycle counting.

Blockchain Technology

Blockchain technology is a secure, automated network that uses cryptography to record data transfers in blocks on a public digital ledger. Though still in its early stages, blockchain offers sophisticated data authentication, validation, and transparency that can significantly impact warehouse operations and inventory management. With shared data storage accessible to all participants within the secure network, blockchain databases could allow every entity in complex supply chains to connect and exchange permanent, automated records for each transaction.

Mobile Shelving

Amazon is a prominent example of a company adopting GTP systems driven by AGVs and AGRs. Their fleets of autonomous robots can replenish mobile shelving units with stock and transport them to designated locations. This setup allows employees to pick orders with minimal walking or physical activity required.

Autonomous Vehicles

Automated distribution centers and warehouses are increasingly using autonomous robotic forklifts. It is also expected that automated delivery trucks will extend their reach further up the supply chain, transporting merchandise between warehouses, manufacturers, and retail outlets.

Fast Shipping

The high demand for rapid online delivery, driven by the "Amazon effect" of one- or two-day shipping, has created a significant need for same-day shipment. This demand continues to drive warehouse automation, which improves the accuracy and efficiency of automated packing and shipping processes and accelerates order fulfillment operations, including picking.

Cleaning in the Warehouse

Industrial automation now includes robotic floor cleaners capable of navigating complex warehouse layouts. A new generation of autonomous mobile cleaning robots is emerging, designed to safely clean and disinfect high-touch areas in distribution centers and warehouses using sanitizing chemicals and UV rays.

Wireless Fleet Management

This capability is made possible by advancements in sensor technologies, cloud databases, and Internet of Things (IoT) applications. Telemetry from onboard computers provides your system with comprehensive information on equipment location, scheduled maintenance, and accident alerts.

ERP Integrations

Machine learning (ML) and API technologies are facilitating the integration of automation solutions with ERP suites, creating comprehensive end-to-end automated business platforms. Further advancements in automation and ERP software will allow back-office workers to focus on tasks that are more value-added, creative, and customer-oriented.

IoT (Internet of Things)

RFID sensors, while not new, remain a crucial element in advancing IoT applications that optimize supply chains and warehouse operations. IoT technology enhances warehouse visibility by providing real-time location information for inventory and equipment. The portability, cost-effectiveness, and real-time tracking capabilities of RFID sensors significantly improve data collection and integration across systems.

Big Data

The development of cloud-based databases and applications capable of collecting, analyzing, and storing large datasets will advance data analytics for warehouse operations. These technologies make data readily accessible, enhancing insights and decision-making processes.

Chapter 7: What are the applications and benefits of warehouse automation?

This chapter will explore the applications and advantages of warehouse automation.

Applications of Warehouse Automation

Warehouse automation has a wide range of applications across various industries. It is employed in robotics for manufacturing in sectors such as aerospace, automotive, and agriculture, as well as in medical facilities.

Some practical applications of warehouse automation across different industries include:

Barcode scanning - Automated warehouses use barcode scanning and labels to optimize warehouse operations and dominate online retail
Picking automation with goods-to-person (G2P) systems �� These systems make use of autonomous robots to carry packages and products that are loaded on pallets to warehouse employees for order fulfillment.
Back office automation - Warehouse management systems that have digital automation features can make use of back office operations.
Inventory automation with retrieval systems - These systems are capable of transferring as many pallets as over five hundred in an hour to their respective dispatch areas.

Benefits of Warehouse Automation

The advantages and benefits of an automated warehouse system are numerous. Modern warehouse technologies are more scalable and user-friendly compared to older automation solutions such as conveyors.

Conveyors are fixed and bulky, whereas operators can rent additional robots to handle increased demand during peak periods and return them when demand decreases. Collaborative mobile robots require no infrastructure changes. Other benefits of warehouse automation include increased productivity and reduced worker strain and fatigue.

Automated warehouses also lead to fewer injuries. Additional advantages include reduced operating costs, increased accuracy, and fewer shipping mistakes. Automation optimizes space by making use of vertical storage locations that are difficult for humans to access.

The use of drones and certain retrieval systems facilitates access to higher storage locations. Investing in an automated warehouse proves to be a sound financial decision due to significant cost savings from reduced errors, fewer injuries, and increased productivity.

Conclusion:

Warehouse automation is the process of using automated technology to take the place of repetitive operations. The major objective is to eliminate time-consuming and labor-intensive tasks. As a result, employees are better able to concentrate on crucial jobs like quality control. However, warehouse automation refers to the use of software to replace tasks that are now done manually and does not always entail the employment of robots or other devices. Over time, the use of automated warehouses has immensely benefited civilization. Robotics manufacturing is used by the automotive industry and retail, which are some of the sectors that use this emerging technology. They have seen significant changes with the advent of artificial intelligence that has dramatically increased worker productivity and efficiency.