Let’s learn more about Automatic Warehousing. Traditional warehouses are known by everyone; however, the modern warehousing system is a unique combination of highly innovative automation technologies, thus being a core part of the supply chain. It involves activities such as cross-docking, kitting, palletizing, tagging, identifying products, and storing them in timely and space-efficient manner. In simple words, an automated or automatic warehouse refers to the warehouse whereby a significant portion of the receipt, storage as well as dispatch of activities are implemented without manual handling of goods. Automated warehousing is based on AS/RS (Automatic Storage and Retrieval Systems), automatic robotic systems for item storage and retrieval in a facility. Solutions are also customized as per the industry requirements, such as production storage, cold/deep freeze storage, WIP warehouse, distribution centers, etc. For instance, cranes as good example of AS/RS machines, and racking system.
These days, the design of modern warehouse system proffers infinite innovative options. Factors, such as product type, diversity, number of articles, performance needs and other organizational requirements. Modern technologies are quite affordable offering good logistics solutions as well as attractive ROI to small business organizations as well.
AS/RS can support various forms of loads, combining systems, such as pallet warehouse, mini load systems, carousel and vertical systems, and special load systems. On the other hand, racking system can be designed either as a standalone shelving system, or part of a rack-supported building. The heights could vary between 8 meters and 45 meters, and can be designed combining the characteristics of single deep storage systems, double deep storage systems, multi-deep storage systems and gravity (flow rack) storage system.
Features of Automated Warehouses
- Two face to face metal rack rows, with a narrow aisle in between metal racks
- At the centre of the narrow aisle, lies a raised metal rail
- A tall pole passes through the narrow aisle
- At the bottom of the pole, a carriage travels in an upward or downward position toward the same level of the point of location
- Atop the carriage is built a load-handling mechanism that reaches into the load to recover it
Benefits of Automated Warehouses:
- Enhances product control
- Lessens and maintains records inventory accurately
- Enhances labour productivity
- Avoids excessive product handling
- Enhance existing floor space’s productive capacity
- Lessen product damage through multiple handling, location errors and shrinkage
- Transparent system
- Makes use of less energy comparatively
- Requires less maintenance
- Fosters response time to customer demands
Schemes of Automatic Warehousing
The most commonly offered schemes or tools of automatic warehousing for organizations to reduce cost as well as speed product movement, include Robots, AS/RS, layer-forming palletizes, forklifts, conveyors, transfer cars and RFID, amongst others.
- Robots – Robots are very effective when it comes to using them in a material handling system. They are programmed such that not only the operator can make desired adjustments in its settings, but also add patterns as per the requirements. The programming is based on palletizing primarily, as well as for de-palletizing / re-palletizing layer, to automate creating rainbow pallets – various layers of SKUs on each pallet.
- AS/RS – As we studied earlier, Automated Storage and Retrieval Systems (AS/RS) – the computer-controlled systems can be considered to avail compact, high density systems that help in saving lot of floor space in the facility. This also saves labour, is 99.9% accurate and prevents the products/materials from being damaged. Besides, AS/RS also offers instant access to wealth of information that can be retrieved by logistics and warehouse managers through web links itself.
- Layer-forming Palletizer – These are generally used for high speed applications in sync with handling bags in the wake of importance of pattern quality. While a robot cannot be used for squaring each layer before stripping it onto the pallet in case of handling bags, a layer-forming palletizer can. For a warehouse with fast rates and only one line, layer-forming palletizer works best. However, the trend today is more towards using robots, because of its multiple production lines handling capacity.
- Forklifts – Forklifts are commonly used in automated warehouse systems for truck loading that also use counter-balanced trucks to facilitate external product flow, equipped with RF equipment that allows the operator to communicate with the Warehouse Management System or WMS.
- Conveyors – Conveyors do not need electric controls to achieve zero pressure accumulation, but a motor for maximum lengths of 100 feet (20 zones). They are considered cost effective, in the sense that only a two HP motor is required for up to 100 feet.
- Transfer Cars – Transfer cars can be used to combine multiple pickup/drop off locations with 1-2 in-feed lines into an AS/RS, such as palletizing lines. The Programmable Logic Controller or PLC (a small computer) takes care of control over the machinery, and is programmed such that it can respond to conditions detected by sensors.
- RFID – RFID, as we have read before, can be used at the pallet level, unit level or case level. For medium or long-term trend, RFID tags should be implemented at the unit level, to track every single consumer purchase transaction. RFID readers can easily be integrated into any form of AS/RS for pallet as well as product identification on a pallet; the data thereof can be then used subsequently throughout the supply chain management. RFID is one another scheme of automated warehouse system that facilitated identifying a product without any visual reference attached to it.
- Pallets – Pallets made of plastic are very much in fad. Being more automation-friendly, they are easy to move on conveyors, yet expensive than wooden pallets. However, in case of a captive system, they are more effective and economic for a long period. Plastic pallets are also used in food applications, where cleanliness is the priority.
