Warehouse automation is the use of digital and physical technology, material handling systems, robotics, and other technologies to automate various operations within a warehouse such as inventory management, order fulfillment and intralogistics. This article will explore the types, benefits, challenges, costs, and best practices for designing and implementing warehouse automation systems and explain how they are rapidly transforming the way warehouses operate in today’s modern economy.
Implementing warehouse automation helps address many common challenges that warehouses face, including:
By implementing warehouse automation, companies can address these challenges and improve their warehouse operation and overall supply chain efficiency and resiliency.
There are several high-level categories of warehouse automation that can be considered when designing and implementing automation within a warehouse:
1. Material Handling Equipment (MHE)/Material Handling Systems (MHS)
This category of warehouse automation includes systems that can move material and transport goods within a warehouse, reducing labor content associated with those functions. These systems include:
2. Inventory management automation
This category of systems enables greater inventory accuracy and more sophisticated operations through better use of data, enhanced location management, and reduced errors. It includes:
3. Order Fulfillment Automation
This category of systems can reduce labor content, increase order accuracy, and enhance consumer experience, and includes technologies such as:
4. Data Analytics, Artificial Intelligence, Data Science, and Digital Warehouse Optimization
This category includes software tools, algorithms, and visualization systems that collect and analyze real-time transactional data throughout the entire operation to optimize warehouse operations such as material flow patterns, inventory levels and utilization, labor balancing, fulfillment cycle times, and real-time coordination with outbound shipping schedules. Warehouse Execution Systems (WES), often span multiple categories of warehouse automation including this one.
5. Custom Automation
This category of automation provides solutions to problems where a standard option doesn’t exist, and a custom-engineered solution specifically designed to meet the unique needs of a business is warranted and cost-justifiable. Businesses should understand that not every solution provider is positioned well to build and implement custom automation solutions.
By understanding these high-level categories of automation, businesses can increase their understanding of how each of these categories can positively impact their supply chain.
Now that we have a good understanding of the high-level categories of warehouse automation, the following is a more granular outline of physical warehouse automation. While we will dive more deeply into Inventory Management, Data Analytics, and Custom Automation categories in future blogs, this article will focus on Material Handling Equipment and Order Fulfillment categories:
1. Conveyor Systems
Conveyor systems have many different applications inside and outside warehouse operations. Within distribution warehouses, conveyor systems can move pallets, boxes or cartons, totes, and sometimes discrete “eaches” throughout a warehouse. This movement reduces the labor associated with these tasks. Types of conveyor systems applicable to warehouse operations include:
The top conveyor manufacturers include Dematic, Honeywell-Intelligrated, TGW, Hytrol, Daifuku, Itoh Denki, and Interroll. Each of these conveyor suppliers are capable of manufacturing multiple types of conveyors and can be considered for a variety of applications.
2. Sortation Systems (Routing and Shipping Sortation)
Sortation systems directly reduce the labor associated with sorting cartons, totes, or “eaches” in a warehouse operation. There are different types of sortation systems including:
The top manufacturers of sortation systems overlap quite significantly with the conveyor system manufacturers listed above, but also include additional suppliers such as Beumer, Crisplant, Korber, Ferag, and others.
3. Unit Sortation
Top manufacturers for this warehouse automation include SSI Schaefer, Dematic, Knapp, Ferag, Beumer, and others.
4. Automated Storage and Retrieval Systems (AS/RS)
Automated storage and retrieval systems are a broad category of warehouse automation that span many different storage mediums including pallets and pallet boards, referred to as “unit load” ASRS, and totes, bins, and cases, referred to as either mini-load ASRS or goods to person. ASRS removes labor content associated with finding and accessing inventory, i.e., time spent walking or driving, and can also greatly increase storage density. Unit load and mini-load ASRS are capable of supporting very tall building heights, drastically increasing storage density.
5. Goods to Person Systems (GtP)
Goods to person systems are a subcategory of ASRS but are noteworthy to call out on its own due to its maturity and rapidly increasing adoptability for order fulfillment warehouse automation.
There are many goods to person systems on the market including AutoStore, OPEX Perfect Pick and Infinity ASRS, Attabotics, Exotec SkyPod, Murata Machinery Ledger, SSI Schaefer SCS, Dematic Multi-Shuttle, Knapp OSR, Swisslog CarryPick, and Vanderlande Adapto.
Additionally, AGVs and AMRs can be applied in goods to person applications. Each of the GtP systems outlined above can reduce labor for order fulfillment and increase storage density.
6. Automated Guided Vehicles (AGV)
AGVs automate material movements throughout the warehouse by automatically transporting pallets, trolleys, or tooling within an operation. AGVs are a mature technology with a deep history in manufacturing. Historically, AGVs navigate by sensing an external system of magnets, reflectors, tape, or wire within its operating envelope.
7. Autonomous Mobile Robots (AMR)
AMRs, although like AGVs, are typically smaller than AGVs and contain more sophisticated navigation and routing capabilities. AMRs can be deployed in a wider range of applications ranging from discrete order picking, carton sortation, material delivery, and inventory inspection.
Some of the leading AMR suppliers on the market include HAI Robotics, Grey Orange, Geek+, Caja Robotics, and Invia Robotics.
8. Packaging Automation
Packaging automation encompasses a wide range of technologies spanning automated carton erectors, random height case sealers, cold seal machines, poly bagging machines, stretch wrapping and shrink-wrapping machines, and right sizing technology.
Right sizing technology effectively cuts or shrinks the shipping container around the order contents, thereby eliminating the need for void fill and optimizing the transportation costs with the smallest possible dim weight.
9. Robotic Picking
Robotic picking within a warehouse includes robotic case picking, layer picking (multiple cases on a single layer of a pallet), and robotic each picking. Using fixed robotic arms with a specialized end effector, robots can mechanically grip whatever object they need and place it on outgoing totes, containers, pallets, or other robots. Robotic vision systems combined with machine learning algorithms can greatly enhance the reliability and range of variability robotic picking can apply to.
Robotic picking eliminates nearly all the labor content associated with picking items in a warehouse.
10. Truck Loading and Truck Unloading
Unloading and loading trucks are fundamental to every warehouse operation. These manual and often ergonomically challenging tasks can be augmented with semi-automated options such as expandable flexible conveyors or telescopic conveyors to automatically convey cases out of or into trucks. Additionally, fully automated truck unloading and loading is a growing space, although far less mature than the semi-automated options on the market.
11. Robotic Palletizing and Depalletizing
12. Weight, Scan, and Dimensioning Systems
Weight, scan, and dimensioning systems are systems that replace the manual identification of an order carton’s barcodes, weight, and dimensions for ship manifest processes. Often these inputs are needed to calculate proper dim weight and costs, and can be used to rate shop and determine the lowest cost method of shipping.
These systems are typically placed in line on a conveyor system where cartons automatically convey across an in-motion scale, through a scan tunnel for automatic identification and data capture (AIDC), and pass under a dimensioning system to acquire the carton’s dimensions.
13. Automated Print and Apply (PandA)
Automated print and apply systems work in tandem with a WMS and or WES system, an upstream weight, scan, and dimensioning system, and place the shipping labels onto outgoing order cartons much faster than manual operations.
Automated print and apply can also be used to place other labels on cartons or eaches for value added services (VAS), special markers or identifiers, or any custom application.
14. Light-Directed Picking (Pick-to-Light and Put-to-Light)
Light directed picking enables increased productivity and order accuracy by clearly identifying the location of interest in pick or put function in order fulfillment. This technology can be used on the face of inventory slots for picking directly from inventory locations. It can also be used at a put wall where cubbies are arranged with lights to help workers sort a batch of product down to discrete orders.
15. Automated Order Verification Systems
Automated order verification systems inspect each discrete unit within an order or order batch to ensure that the right item has been picked. This technology utilizes a combination of vision systems, barcode scanning, weighing, and other sensors to compare expected inventory to actuals to determine high confidence of order accuracy. This type of system prevents the wrong items from being shipped to the customer and is vital to high value and high regulatory settings such as pharmaceutical order fulfillment.
16. A-Frame Dispensers
A-frame dispensers are a technology that stores inventory in an A-shaped frame over the top of a conveyor. Discrete units are dispensed from individual cartridges that make up this frame directly onto the conveyor. A-frame dispensers can be used to automatically pick discrete orders or a batch of orders. They are typically deployed in high volume warehouses with small items that are compatible with the narrow cartridges and dispensing mechanisms. The pharmaceutical and cosmetic industries are the most likely industries to benefit from this technology.
17. Automated Order Consolidation Systems
Automated order consolidation systems overlap significantly with unit sortation systems, although there are some differences in that consolidation can be done via robotics, conveyors, or shuttles such as Opex’s Sure Sort technology. The purpose of the technology is to establish order integrity, consolidating all the contents of an order in one location, so that it can be packed and shipped out of the warehouse.
Download the table here.
While deploying warehouse automation unlocks significant value for most businesses, it’s not without challenges. Here are a few challenges associated with warehouse automation that you and your warehouse automation partner should proactively manage:
Most distribution fulfillment warehouses consist of the following processes, each with a varying degree of viability for warehouse automation contingent on several factors:
| Process | Automatable
[1 – 4] |
Example Automation |
| Truck unloading | 2 | Robotic truck unloading |
| Receiving | 4 | Receiving sortation system |
| Put-away | 3 | Pallet put-away by AGV |
| Case picking | 4 | Auto pick by shuttle or mini-load ASRS |
| Each picking | 2 | Robotic each picking or A-frame dispensers |
| Replenishment | 3 | Shuttle system replenishment to back of carton flow |
| Order consolidation | 2 | Unit sortation or automated put wall |
| Packing | 3 | Poly baggers, right sizing machines, and document insertion |
| Shipping/manifesting | 4 | Automated print and apply |
| Truck loading | 2 | Robotic truck loader |
The cost of warehouse automation can vary substantially on several factors including complexity, size of the warehouse, storage capacity, throughput capabilities, and market maturity. It’s also important to understand the total cost of ownership, not just the upfront capital costs. Total lifetime cost of warehouse automation should consider:
Implementing warehouse automation within your facility should follow a process that (i) seeks to meet your business and operational requirements, (ii) satisfies future growth and compositional changes to the business, and (iii) provides a compelling return on investment.
The overall project lifecycle of implementing warehouse automation should be led and managed by competent professionals with expertise in operational design, industrial automation, systems integration, construction, and risk management. A recommended path to automate your warehouse is found below in an example project life cycle:
Step 1: Strategy and Feasibility
Step 2: Conceptual Operations Design
Step 3: Detail Design
Step 4: Implementation
Step 4: Acceptance and Turnover
So, when should you automate your warehouse? By the time most businesses realize they need to invest in warehouse automation or increase their current use of business automation, it’s likely pain is already being realized. See best practices below to learn the importance of planning ahead.
1. Plan
The timeline to implement warehouse automation can vary from a few months up to 2 years for large projects.
2. Develop a Strategic Roadmap
Your strategic planning should integrate an automation roadmap for your facility and network.
3. Work With a Strong Partner
Signs that you’ve identified the right partner:
4. Evaluate Multiple Suppliers
Individuals and organizations alike have tastes and preferences, even for warehouse automation. Often, there can be a strong predisposition to use a particular supplier or technology. It is best to consider multiple options and evaluate those options using a methodology that is analytically robust and yields a pragmatic result.
5. Establish a project structure
For all projects, but particularly larger capital projects and complicated retrofits, it’s important to define the overall project for each workstream involved. Typically, a project would have up to 9 workstreams, each with a dedicated lead identified to ensure the success of that workstream and would report up to a Program Management Office or “PMO”. These workstreams are:
Each of these workstreams should report up to the PMO where the project owner holds responsibility for the overall program.
Warehouse automation is fundamentally changing how distribution centers and warehouses operate. The financial justification for warehouse automation is becoming increasingly clearer and more compelling. Companies that work with the right partner to develop an automation strategy and integrate warehouse automation will have superior operating efficiency and potential over time.
