Best Applications to Automate in Warehousing

Automation is an essential part of many industries today, thanks to advancements in technologies like the Internet of Things (IoT) and artificial intelligence (AI). Processes need to be efficient throughout the supply chain, especially in warehousing, to remain competitive in the industry.

With many businesses automating part or most of their warehouse operations, now is the time to make the shift. This guide highlights warehouse automation solutions and everything you need to know to future-proof your systems.

What Is Warehouse Automation?

Warehouse automation refers to the use of technology to perform operations in a warehouse and reduce or fully replace human intervention. These technologies fall into two categories that work together to increase efficiency, including:

• Digital automation: The use of digital systems and software to perform repetitive tasks and complex data exchanges. These solutions help reduce manual data entry and management.
• Physical automation: The use of machines and other apparatus to perform manual labor, reducing physical demands and employee movement in the warehouse.

Why Is Automation Important in Warehousing?

Automating warehouse operations has many clear benefits centered around efficiency and customer satisfaction.

If you’re looking for reliable warehouse solutions that take your business to the next level, consider these key benefits of automated warehouses that highlight the value of automated systems:

• Improved efficiency: Efficiency is one of the most important aspects of warehousing. Automated systems can improve efficiency by streamlining and speeding up repetitive and complex tasks.
• Increased accuracy: Human error can be costly in warehousing. Automating processes like inventory management, data entry and order sorting improves accuracy, resulting in fewer mistakes.
• Reduced labor expenses: A recent survey on warehousing costs and fulfillment found that labor costs represent 28.43% of total revenue. Investing in automation is the best way to lower expenses that go toward human labor, as you’ll reduce reliance on manual work and bypass certain roles that traditionally needed human intervention.
• Enhanced safety: The risk of workplace injuries is higher where there’s a heavy reliance on human labor. By reducing movement and automating heavy or dangerous tasks, you enhance safety.
• Optimized warehouse space: Utilizing automated storage and retrieval systems helps to maximize warehouse space.
• Simplified scalability: Scaling warehouse operations the traditional way means increasing labor, which, in turn, increases operational expenses. Automation allows scaling or adapting operations in response to market conditions without increasing your spending.

Types of Warehouse Automation Processes

There are many aspects of warehousing you can automate due to the availability of diverse technologies that enable automation, from software solutions to hands-free advanced robotics.

Here are some of the processes to automate in your warehouse.

Inventory Management

There are a number of ways to automate inventory management and reduce the tedious tasks associated with tracking and optimizing stock levels. One of the key digital automation tools you need is a robust warehouse management system (WMS).

WMS software acts as an end-to-end inventory management solution that provides real-time visibility and control over inventory levels and movement. It can also integrate with other solutions like corporate enterprise resource planning (ERP) systems.

Receiving

Receiving and handling goods is one of the areas that usually suffers from inefficiency. These processes can benefit from warehouse automation technology in many ways, such as:

• Data collection: The use of radio frequency identification (RFID), barcode scanners and computer vision can help automate the identification of items for sorting and data management.
• Weighing: Manually weighing goods and recording data can be labor-intensive and time-consuming. Smart sensors can help capture accurate information about incoming products.
• Storage and retrieval: You can now eliminate or significantly reduce manual labor demands with automated storage and retrieval systems (AS/RS). These are computer-controlled equipment such as cranes, shuttles and robots that place, retrieve and organize goods in the warehouse.
• Handling: Operator assistance technologies like automated guided vehicles (AGV) and autonomous mobile robots (AMR) follow specific routes around the warehouse, supporting human processes and handling goods.

Order Fulfillment

Order kicking and fulfillment can use a wide range of automated warehousing systems to streamline tasks by reducing repetitive activities. Goods-to-persons (GTP) tools, like industrial conveyor systems, can help deliver items to the picking station or guide workers to the correct products.

Other technologies that can effectively automate the order-picking and fulfillment process include:

• Pick-by-voice: Uses headsets and speech recognition to guide workers through tasks like picking and putting away.
• Collaborative robots: Cobots are among the top emerging technologies today. These machines work alongside humans and employ AI to assist workers with diverse tasks.
• Packaging: You can reduce or eliminate manual packaging using machines designed to package, label and prepare goods for shipping.

Warehouse Automation Challenges

Automating warehouse operations gives you a competitive edge in the industry. There are also a few potential challenges to be aware of, including:

• High initial costs: Automating your operations comes with high upfront costs. You’ll need to invest in software, hardware and appropriate infrastructure suitable for those upgrades.
• Integration issues: Merging new automated systems with existing ones can be challenging and will require expert attention. The same goes for hardware and software solutions from different providers.
• Ever-changing technologies: Rapid technological advancements offer convenience. But they can also make your new automated systems obsolete when better innovations emerge.
• Workforce adaptation: Employees may find adapting to new systems and processes to be challenging.

When Should You Automate Your Warehouse?

The decision to automate some or all of your processes should be based on metrics that point to automation as a solution for improvement.

Here are questions to ask yourself to determine if your warehouse is ready for automation:

• Do you consistently keep up with order fulfillment demands?
• Are your picking, packing and shipping processes efficient?
• Do you have a high volume of repetitive tasks taking up valuable time?
• Is there a clear growth plan for the business?
• Does the team struggle to maintain sustainable operational costs?
• Do you have a high rate of errors resulting in losses and customer dissatisfaction?

If you find your current processes could use a boost, automated systems may be the right solution.

3 Trends in Warehouse Automation

Automation is becoming an unstoppable force, transforming modern warehousing due to growing e-commerce demands and the need for speed and efficiency.

Here are the key trends shaping the future of warehouse automation.

1. The Rise of Humanoid Robots

We already have cobots, which work alongside human workers. However, there’s a rise in humanlike robots currently being developed and tested by giant companies like Agility Robotics, Boston Dynamics and Tesla.

These robots are designed to navigate diverse work floor environments and perform heavy, complex tasks alongside humans.

2. Adoption of AI and ML

AI and its subset, machine learning (ML), are a big part of automation in warehouses. The adoption rate for these technologies is set to grow even further in the future as more warehouses seek improved efficiency and adaptability.

3. Automation-as-a-Service (AaaS)

While the upfront cost for implementing automation is high, a new model has emerged that provides small and medium warehouses access to automation without the upfront investment. This model is called automation-as-a-service.

Explore Automation With Gregory Poole

Automating key applications in warehousing, from inventory management and data analysis to product handling, is an effective way to improve efficiency and lower labor costs. By investing in both digital and physical automation solutions, you lay a solid foundation for long-term growth and innovation.

Gregory Poole specializes in comprehensive material handling solutions, offering the latest-in-the-industry equipment and robotics. With our operator assistance technologies, you can automate physical processes in your warehouse with ease.

Contact our expert team to learn how we can help!