Todays warehouses are transforming into dynamic ecosystems
Published on : Sunday 05-05-2024
Asim Behera, President, Daifuku Intralogistics India Pvt Ltd.
What are some of the latest advancements in material handling technology that have significantly improved efficiency in warehouse operations?
Remember the warehouses of yesteryears? Dusty warehouses filled with endless rows of shelves, a reliance on muscle power, and a whole lot of guesswork in managing inventory. But those days are fading faster than end-of-season markdowns.
Today's warehouses are undergoing a metamorphosis, transforming into dynamic ecosystems driven by a powerful interplay of cutting-edge technologies. Warehousing 4.0 represents a complete material handling revolution, fundamentally reshaping how we approach logistics.
The Automation All-Stars:
Gone are the days of siloed automation solutions. Today, it's all about collaboration. Here's the dream team:
High-bay AS/RS: These storage titans leverage stacker cranes for efficient retrieval and storage, maximising space utilisation for palletised goods (unit loads) or smaller items (mini-loads) within towering warehouse bays. Daifuku's high bay AS/RS solutions redefine warehouse capacity. These cutting-edge technology systems, reaching heights of 10 to 40 meters, leverage stacker cranes for efficient retrieval and storage of both pallets (up to 1,500 kg) and smaller items (up to 50 kg). This isn't just about more storage; it's about maximising every cubic meter of your warehouse. Imagine quadrupling your density!
Daifuku's high-bay AS/RS goes beyond one-size-fits-all. Our modular design and multiple configurations ensure a perfect fit for warehouse operation.
Single-deep configuration: Prioritise easy access for frequently retrieved items.
Double-deep configuration: Maximise storage density for less frequently accessed items.
Sorting Transfer Vehicles (STVs): The Seamless Connectors
Picture these as rail-guided workhorses seamlessly integrating with Daifuku's AS/RS and other automation systems. STVs swiftly transport pallets, totes, or individual items along designated tracks, eliminating the need for manual maneuvering and significantly improving throughput. Daifuku's STVs boast an impressive handling capacity, moving between 100 pallets to 600 pallets per hour per loop, revolutionising good-to-person and person-to-good workflows with high speeds, ensuring pickers aren't left waiting.
Agile AMRs: Think autonomous mobile robots as your on-demand sidekicks. Equipped with advanced vision systems, they navigate dynamic environments with ease, handling repetitive tasks like tote and carton transport, freeing up human workers for value-added activities.
Collaborative Cobots: Human-robot collaboration is becoming a reality. Cobots, equipped with safety sensors, work alongside human pickers, tackling tasks like de-palletising and palletising with precision and efficiency.
WareNavi WMS: The Data Powerhouse Fueling WES's Execution
Warehousing Execution Systems (WES) are the new AI-powered dynamos driving efficiency in distribution centers. But even the most powerful engine needs high-quality fuel to run optimally. That's where Daifuku's WareNavi WMS comes in – the data powerhouse that fuels WES's execution capabilities.
WareNavi WMS provides WES with the critical data it craves, including real-time inventory levels for accurate picking and order fulfillment. Historical insights from WareNavi empower WES to predict demand fluctuations, allowing for proactive resource allocation and labour planning. Additionally, WareNavi seamlessly integrates with WES, ensuring smooth data flow and eliminating manual errors.
This dynamic duo – WareNavi WMS and WES – work in tandem to unlock a significant competitive advantage for your DC. Real-time data from WareNavi optimises picking routes for faster fulfillment, while intelligent task allocation by WES minimises wasted labour, leading to reduced costs. Ultimately, WareNavi and WES work together to streamline your entire DC operation, boosting efficiency and putting you ahead of the competition.
The IoT Network:
Warehouse equipment is shedding its silence and becoming increasingly vocal. Sensor-equipped forklifts, AMRs, and STVs constantly transmit a stream of data – equipment health, location, and performance metrics. This real-time data stream empowers predictive maintenance practices, minimising downtime and ensuring optimal equipment functionality. Environmental monitoring sensors join the chorus, keeping temperature, humidity, and other critical parameters in check for ideal storage conditions.
Next-Gen Conveying Systems:
High-speed sortation systems with sophisticated mechanisms like tilt trays, shoe sorters, and diverter belts automate high-volume order fulfillment at lightning speed. Goods-to-person (GTP) technologies like put walls and carousels further elevate efficiency by minimising picker travel time, allowing them to focus on accurate picking.
This tech revolution is about harnessing data to create a truly intelligent warehouse. Warehousing 4.0 is about collaboration – a powerful network of technologies working together to achieve peak performance. It's a testament to human ingenuity, and the future of how we handle and distribute goods is bright.
Can you provide examples of how optimising warehouse layout and flow paths can enhance material handling efficiency?
Here are some key examples of how optimising warehouse layout and flow paths can significantly enhance material handling efficiency:
Golden Zone Placement: Frequently picked items are placed in the most accessible locations within the warehouse. This ‘Golden Zone’, typically closest to the packing stations, minimises picker travel time and reduces the number of steps required to fulfill orders. Less frequently accessed items can be stored further away or in higher storage locations.
Minimising Travel Distances: Optimising picking routes by strategically placing similar items together reduces travel time between picking locations. This can be achieved through techniques like ABC classification, where items are categorised based on demand (A- high, B- medium, C- low) and stored accordingly to minimise picker travel for high-demand items.
One-Way Flow Design: Implementing a designated flow for receiving, storing, picking, and packing creates a smooth flow of goods throughout the warehouse. This eliminates congestion and backtracking, where pickers might have to navigate against the flow of incoming or outgoing goods. One-way flow designs can be achieved through designated lanes, aisles, and designated entry/exit points for specific tasks.
Integration with Automation: Optimising layout considers how automation will integrate with human workflows. This can involve strategically placing AS/RS units, conveyor belts, STVs, AMRs, and GTP technologies (put walls, carousels) to ensure a seamless flow of goods between automated systems and picking stations.
Put-Away Optimisation: Optimising put-away processes by considering future picking needs reduces travel time and ensures efficient picking later. For example, storing like-sized items together or storing full pallets closer to picking areas can streamline future order fulfillment.
By implementing these strategies, companies can significantly improve picking efficiency and overall throughput within their warehouses.
The Efficiency Equation:
Faster Order Fulfillment: Reduced travel time, improved inventory accuracy, and streamlined picking processes contribute to faster order fulfillment times.
Reduced Labour Costs: While there's an initial investment, the long-term benefits often outweigh the cost. Increased worker productivity, reduced injuries, and potentially lower labour requirements due to automation can lead to significant cost savings.
What strategies do companies employ to integrate material handling equipment with inventory management systems for better tracking and control of stock levels?
Manual processes and siloed data systems create blind spots, hindering our ability to truly optimise inventory control. IMS acts as the single source of truth for your entire inventory picture, providing data on SKU levels, distribution centre locations, and reorder points. This information feeds seamlessly into the WMS, which then translates it into actionable warehouse processes. Imagine your IMS as the central nervous system, constantly monitoring stock levels across your network. The WMS becomes the brain of the warehouse, utilising real-time inventory data to automate tasks like picking algorithms, cycle counting, and directed put away strategies. This integrated approach ensures your warehouse activities are tightly coupled with your overall inventory strategy, leading to improved fulfillment accuracy, reduced carrying costs, and enhanced demand forecasting.
WareNavi: Supercharge warehouse with a Feature-Packed WMS
1. End-to-End Visibility & Control: WareNavi isn't just another WMS; it's a command center for your entire distribution center (DC). It streamlines inbound receiving, putaway, order fulfillment, outbound shipping, and more – all under one roof. Achieve seamless integration with your warehouse infrastructure, including automated storage and retrieval systems (AS/RS), conveyor networks, sortation systems, and warehouse robots. Plus, it plays nicely with traditional setups like fixed racking and forklift operations.
2. Real-Time Visibility & Actionable Insights: Forget the spreadsheets and embrace a dynamic digital dashboard. Get a bird's-eye view of your DC's health, allowing for proactive intervention in case of bottlenecks or throughput issues. Granular work progress monitoring by area, operation, and even individual worker. Identify performance gaps and optimise workflows for maximum efficiency. Leverage a robust alert system to stay ahead of potential problems and minimise downtime.
3. Data-Driven Decision Making: WareNavi goes beyond basic inventory management. It equips you with powerful business intelligence (BI) tools like ABC analysis for optimised product placement based on SKU velocity. Gain insights into workload distribution across different periods. Work performance analysis helps identify top performers and areas for improvement. Inventory turnover rate calculations provide valuable data for informed stock management.
4. Adaptable to Your Dynamic Needs: WareNavi understands that warehouses are living organisms. Even after implementation, you can fine-tune the system to your evolving needs. Need to add more fixed racking or modify receiving inspection procedures? WareNavi adapts on the fly.
5. Role-Based Access & Enhanced Security: WareNavi prioritises security with granular user permission controls. Restrict access to specific functionalities based on an individual's role, preventing unauthorised actions. Multi-factor authentication options like IC cards, color barcodes, and even biometrics ensure only authorised personnel can access the system.
The true power lies in the data. Integration unlocks a treasure trove of insights into inventory movement patterns. Armed with this knowledge, we can make data-driven decisions about future inventory planning, purchasing strategies, and even optimise warehouse layouts for maximum efficiency.
In your experience, how does the integration of robotics and automation impact labour efficiency and overall operational costs in warehousing?
I've witnessed countless trends come and go. But the rise of robotics and automation isn't a passing fad – it's a full-blown revolution. It's fundamentally reshaping how we approach efficiency and cost control in our warehouses, and let me tell you, it's an exhilarating ride.
From Marathon Pickers to Empowered Teams: Forget the dystopian visions of robots stealing every job. The reality is far more strategic. Automation tackles the repetitive, physically demanding tasks that drain human energy and focus. Imagine this:
Pickers Unleashed: High Speed Sorting Transfer Vehicles (STVs) and Autonomous Mobile Robots (AMRs) become the tireless runners, fetching goods and delivering them directly to pickers. This frees up your team to focus on higher-value activities like kitting and value-added services, maximising their expertise and human touch.
Ergonomics on Steroids: Heavy lifting and precarious ladder climbs become relics of the past. Robotic arms and Automated Storage and Retrieval Systems (AS/RS) take over these physically demanding tasks, reducing workplace injuries and boosting worker well-being.
The Cost Equation: A Multi-Faceted Advantage
While the initial investment in robotics and automation can be significant, the long-term cost savings are undeniable. Here's where the real magic happens:
· Labour Optimisation: Automation allows for smarter staff allocation, potentially leading to a smaller team focused on higher-value activities. Helps HR Managers to plan and allocate teams efficiently.
· Faster Throughput, Tighter Footprint: Automation accelerates picking and packing processes, allowing you to fulfill orders faster. This translates to potentially needing less warehouse space, as faster movement means you can optimise storage utilisation and potentially downsize your footprint. Less space means lower rent or ownership costs, freeing up capital for strategic investments.
· Inventory Accuracy on Autopilot: Robotics and automation minimise error in picking and put-away processes. This not only reduces shrinkage and product damage but also ensures you have the right inventory on hand, leading to fewer stockouts and potential purchasing cost savings.
· Customer Satisfaction Soars: Faster order fulfillment and improved inventory accuracy translate to happier customers. In the age of e-commerce, speed and reliability are the new currency.
· Scalability for Growth: On-demand robotic systems are like building blocks – modular and easily scaled up or down as your business grows. This agility allows you to adapt to changing market demands without major infrastructure overhauls.
The future of warehousing lies in a collaborative environment where humans and robots work together, leveraging the unique strengths of both. Human ingenuity meets robotic precision to create a truly intelligent and efficient warehouse ecosystem. It's not about replacing humans; it's about empowering them to do their best work.
What are some key safety considerations and best practices in material handling and warehouse operations, particularly when implementing automated systems?
Today, automation emerges as the new engine of efficiency. Yet, one principle remains our guiding star: safety. It's not a peripheral concern; it's the very foundation upon which a successful, high-performance warehouse is built. The critical question is this: how do we harness the power of automation while safeguarding the well-being of our most valuable asset – our people?
Human-Machine Collaboration: A Delicate Balance
Imagine a warehouse where human-machine interaction (HMI) is seamless, but with a critical distinction: segregated zones. We achieve this through:
Physical Segregation: Designated zones with safety barriers, signage, and floor markings create buffer zones, minimising the risk of accidental collisions between personnel and automated equipment.
· Access Control Systems: Restricted access control systems (RACS) become our gatekeepers. Entry into automated zones is strictly limited to authorised personnel only, ensuring only trained individuals can access these areas for maintenance or troubleshooting.
· Comprehensive Training: In-depth training on safe interaction with automated systems, emergency shutdown procedures, hazard identification, and proper use of Personal Protective Equipment (PPE) becomes the bedrock for a synchronised operation.
Safety: A Cultural Cornerstone
Safety isn't a slogan; it's a core tenet ingrained in a company culture. Here's how we cultivate it at Daifuku:
· Zero-Tolerance for Risks: A clear zero-tolerance policy for safety violations sends a resounding message – safety is an absolute priority.
· Regular Risk Assessments: Regular safety audits are like ongoing risk assessments, proactively identifying and mitigating potential hazards before they become incidents.
· Learning from Incidents: We foster a culture of open communication where safety incidents are reported and investigated thoroughly. Every incident becomes a learning opportunity, preventing future occurrences.
Seamless and Safe Automation Integration
Automation isn't just added; it's seamlessly and safely integrated. Here's how:
· Risk Assessments: The Precursor to Automation: Before any automated system enters our facility, comprehensive risk assessments are conducted. We identify potential hazards and develop mitigation strategies to address them proactively.
· Emergency Stop Systems: A Universal Safety Measure: Imagine readily accessible and clearly labeled emergency stop buttons on all automated equipment. It's a universal safety control, ensuring immediate action can be taken if needed.
· Preventative Maintenance: The Unsung Hero: A robust preventative maintenance program becomes our unsung hero. We regularly inspect and service all material handling equipment, both automated and manual, minimising the risk of breakdowns or malfunctions.
Investing in safety isn't just the right thing to do; it's a smart business decision. By prioritising safety and adhering to these best practices, we can ensure automation empowers our workforce, not endangers them. The future of warehousing is a collaborative environment where humans and machines work together to create a safe, efficient, and high-performing ecosystem. Let's embrace this exciting future, but always remember – safety is the foundation upon which everything else rests.
(The views expressed in interviews are personal, not necessarily of the organisations represented.)
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