What is Warehouse Automation? How to Make Your Facility More Efficient (2024)

When you think of a warehouse, you might conjure up images of high-tech facilities equipped with autonomous robots, sophisticated conveyor systems, and intelligent warehouse management systems that control all operations.

In reality, most warehouses are more manual, with workers walking the aisles taking orders and managing inventory using paper-based systems and basic software. For some businesses, a simple pen-and-paper system works well, but for others it’s costly and prone to errors.

Warehouse automation can transform an inefficient facility into a streamlined, technology-driven operation. Here we take a closer look at the benefits of warehouse automation, the types of warehouse automation technology on the market, and advice for automating your facility.

What is Warehouse Automation?

Warehouse automation is the use of technology such as robots, conveyor systems and software to automate processes within a warehouse. WarehouseThese tools streamline operations by automating the storage, retrieval and movement of inventory, managing data and directing workers.

The goal of warehouse automation is to improve efficiency, accuracy, and productivity compared to manual processes, reduce costs, and Customer Satisfaction.

Types of Warehouse Automation Technology

Warehouse automation includes a variety of tools to streamline and optimize warehouse processes. From robotic systems to software solutions, common warehouse automation technology types include:

Goods-to-people (GTP) technology

Goods-to-people (GTP) technology automates item retrieval using robotic shuttles or carousels to retrieve items from storage and deliver them to a workstation or designated storage location, where a human performs the remaining tasks. Inventory control.

Automated Storage and Retrieval Solutions (AS/RS)

Automated storage solutions (AS/RS) are computer-controlled systems made up of different types of equipment, such as vertical lift modules, horizontal carousels, and small parcel AS/RS, designed to store and retrieve small items without human intervention.

Automated Guided Vehicles (AGVs)

An automated guided vehicle (AGV) is an unmanned, computer-controlled vehicle that follows predefined paths to transport goods within a warehouse. AGVs can move pallets, rolling carts, and individual items, and are often integrated with other automation systems to create a seamless material handling process.

Autonomous Mobile Robots (AMR)

Autonomous mobile robots (AMRs) are more advanced than AGVs because they can move around warehouse environments without fixed paths or infrastructure. AMRs use sensors, cameras, Artificial Intelligence (AI) It perceives its surroundings, avoids obstacles and plans routes for tasks such as picking, transporting and sorting items.

Pick-to-light and put-to-light systems

Pick-to-light and put-to-light systems use lights and displays to guide workers to the correct location for picking or storing items. These systems improve accuracy and efficiency by providing visual cues, reducing the need for workers to search for items or refer to paper-based instructions.

Audio Picking and Audio Tasks

Voice picking and voice tasking technology uses voice recognition and voice commands to guide workers through various tasks within the warehouse. Workers wear headsets and can receive voice instructions and confirm their actions, allowing hands-free operation and reducing errors associated with manual data entry and paper-based processes.

Automatic sorting system

Automated sortation systems use crossbelt sorters, tilt tray sorters and sliding shoe sorters to separate items and route them to designated locations within the warehouse. These systems identify, orient and guide items to their appropriate destination.

Drone

Drones are emerging as a promising technology for warehouse automation. These aerial robots monitor inventory, track assets, and pick up small items in hard-to-reach places in warehouses.

Benefits of Warehouse Automation

Warehouse automation improves performance and profitability. Key benefits include:

Increased productivity and efficiency

Automation technology enables faster, more accurate picking, packing, and shipping. Warehouse automation systems, including robotic picking arms, automated storage/retail systems (AS/RS), and conveyor belts, operate around the clock to minimize human error and maximize productivity.

Integrating these automation systems Warehouse Management Software (WMS) This enables real-time inventory tracking, optimized product placement, and efficient order routing, further increasing productivity and efficiency.

Reduce labor costs

Automating warehouse operations reduces the need for manual labor, a major cost of running a warehouse. Basic warehouse automation solutions like conveyor systems and barcode scanners minimize manual processes, while more advanced technologies like autonomous mobile robots (AMRs) handle tasks like picking, transporting, and sorting items with minimal human intervention.

This enables warehouses to operate with a smaller workforce, resulting in significant savings in labor, benefits and training costs, while mitigating the impact of labor shortages and high employee turnover.

Improve inventory accuracy and control

When integrated with automation technology, warehouse management systems can provide real-time visibility. Stock LevelsKnowing inventory, location, and movement enables warehouse operators to maintain accurate inventory counts and minimize discrepancies.

Barcode scanner or Radio Frequency Identification (RFID) The reader ensures that every item that moves through the warehouse is accurately tracked and recorded, reducing the risk of human error from manual data entry.

The AS/RS locates and retrieves items, eliminating the need for manual searches and reducing the risk of misplaced stock, resulting in improved and more efficient inventory management. Order Fulfillment.

Scalable and flexible for growth

Automating your warehouse systems allows you to adapt to changing market demands and scale your operations without major disruptions or additional effort.

Modular, flexible automation solutions like AMRs and configurable conveyor systems can be deployed quickly and reconfigured to suit inventory fluctuations, order volumes and product mix, helping you maintain performance during peak periods and new product introductions.

How to automate your warehouse

1. Evaluate your current processes
2. Develop a strategy
3. Choosing an automation technology
4. Train your team
5. Monitor your automation efforts

Because every business has its own needs and particularities, consider customizing this generic step-by-step guide to your specific requirements.

1. Evaluate your current processes

Before implementing automation, assess your existing warehouse operations to identify bottlenecks, inefficiencies, and areas that would benefit most from automation. Analyze key metrics such as: Order Processing Analyze time, inventory accuracy, and labor costs to establish a baseline for measuring the impact of automation.

Work with employees across departments to gather these insights and identify pain points that can be solved through automation.

2. Create a strategy

Based on the assessment, we will create a detailed automation strategy that fits your needs. Business ObjectivesPrioritize projects based on time, budget, and long-term vision Return on Investment (ROI)ease of implementation, and impact on overall warehouse performance.

Create a step-by-step implementation roadmap that outlines the steps, timelines, and resources required to successfully deploy your automation solution.

3. Choose your automation technology

Research automation technologies to determine which best suits your specific warehouse requirements.

Companies dealing with large volumes of small item picking can choose an AMR solution for precise navigation and efficient item selection, while companies dealing with large stocks of palletized goods can benefit from an AS/RS system for fast and accurate storage and retrieval of pallets.

When selecting an automation system, prioritize scalability, flexibility, and vendor support. Schedule informational meetings with experts, attend industry conferences, and participate in webinars and workshops to glean insights about the best technology for your warehouse.

4. Train your team

Automation often requires significant changes to existing processes and roles in the warehouse. Invest in training programs to ensure workers have the skills and knowledge to operate and maintain automated systems. Develop a change management plan that communicates the benefits of automation and drives continuous improvement.

When investing in training for your warehouse automation implementation, consider incorporating the following elements:

• Hands-on training to familiarize workers with operating, maintaining and troubleshooting the new automation system.

• Comprehensive safety protocols and best practices for working with automated equipment.

• Training on software systems that control and monitor automated equipment and interpret data.

5. Monitor your automation efforts

Once your automation solution is implemented, monitor its performance and its impact on key warehouse metrics. Use data analytics and reporting tools to identify areas for further optimization and fine-tune your automation system to maximize efficiency and productivity.

As your business expands, continually reevaluate and enhance your automation strategy, explore new areas in your warehouse, and integrate new technologies to stay competitive.