Automation of warehouse processes is a natural consequence of the ongoing digital transformation. Its goal is to increase the efficiency of the company, the safety of employees and lower labor costs. More and more companies are choosing modern solutions that improve logistics processes. So we explain what and how can be automated.

Automation of logistics processes – warehouse 4.0

In the so-called of the fourth industrial revolution, the main role is played by the integration of machines with the Internet and information technologies. In our industry, the impact of digitization is also clearly visible, which is reflected in terms such as logistics 4.0 or warehouse 4.0 . In order to remain not only effective, but also competitive in the modern market, the automation of warehouse processes (including logistics) is a must today.

Warehouse automation can be introduced at any time during the company’s operation . The return on investment speaks for it, which takes place just a few years after the implementation of significant changes in the logistics of warehouse management. The automation of warehouse processes includes the storage, preparation and shipment of goods, but you do not have to make changes in all areas immediately. You can seamlessly switch to a better, modern version of the magazine.

Automation of warehouse processes

Warehouse processes that can be automated include:

• storage, transport and distribution of goods,
• completing, packing and order fulfillment,
• control of the condition and demand for individual materials.

All these processes, both in the analog and digital versions of the warehouse, are managed by logistics, which can be automated.

Automated warehouse: cargo handling

One of the areas that can be automated in a warehouse is goods handling, such as unloading, stacking and moving goods. The main role in this process is played by automatic stacker cranes – devices that place and remove goods from rack installations (pallets, containers, containers and others). They move on rails on the floor, from where they place or pick up loads in a specific location.

The “brain” of the stacker crane is a microprocessor, thanks to which it can be properly programmed. Particular devices differ in the time of the load handling cycle (e.g. removing it from the rack), the permissible load and dimensions of the loads, the length of the telescopic forks, the depth of the supported racks and the type of mechanism (grapple, forks, conveyor).

We achieve the best results and a high level of automation when we allocate one stacker crane for one narrow aisle . In addition, the warehouse should be equipped with other transport systems, such as conveyors (which enable the transport of loads even between the storeys of the warehouse and the unloading and loading of trucks), rail suspension systems or shuttle carts. 

Automated warehouse: goods quality control

Automation of processes in the warehouse also includes checking the quality of individual loads. If there are stands integrated with lifts in the come zone, the condition, size and weight of the goods can be checked automatically .

Automated warehouse: order picking

Automatic preparation of goods for shipment consists in wrapping and labeling the pallets before transporting them. The manual work of operators can be replaced by the installation of manipulators that can cope with heavy and large loads much better than a human .

IT systems – automation and control of the equipment issuance process

Warehouse management systems are modern applications without which the automation of warehouse processes would be impossible. One of the solutions intended for warehouse spaces are programs for issuing resources to employees. An example of an IT system is the IDS software, which supports modern vending machines that deliver to the warehouse .

The automatic system for issuing equipment to employees requires a minimum of service, and provides full records of the flow of goods collected by operators for daily work in the warehouse – tools, personal protective equipment, health and safety products or consumables.

IT systems for warehouse management can control all logistic processes. The change in efficiency is especially noticeable when operators handle a wide variety of shipments from multiple senders and directed to many recipients. Free but safe flow of information allows you to control all operations in real time and prevents downtime.

Automation of work organization in the warehouse

Warehouses can function thanks to employees. Improving their work will therefore increase the efficiency, safety and precision of order fulfillment. Automatic warehouse management systems are used for this, which provide information on the efficiency of employees and the course of warehouse processes. Thanks to this, it is known what needs improvement and which processes take the longest time for operators .

Automating the organization of warehouse work also means controlling the status, flow and demand for goods. IT systems verify the characteristics, storage location and quantity of stocks . The supply chain can therefore be improved on an ongoing basis and any errors eliminated.

Benefits of warehouse automation

Automation of warehouse processes is associated with capital investment, but the opportunities for the company make it a 100% profitable and long-term investment . The implementation of automation in warehouse processes brings the following benefits:

• Replacing forklifts with automatic stacker cranes allows you to handle more loads at the same time.
• Automation of warehouse processes means better use of warehouse space. Stacker cranes can handle high bay installations which significantly increase the amount of space for loads. On the other hand, forklifts cannot manipulate goods in very high halls and do not allow the maximum use of the warehouse space.
• Machines supporting repetitive, monotonous, and at the same time demanding human work, reduce errors in order fulfillment. Therefore, automation is accompanied by an increase in customer satisfaction and, consequently, the number of orders.
• Machines operate according to the parameters assigned to them, achieving high rates of work efficiency.
• Fast order fulfillment means an intensive flow of loading units through the warehouse and greater efficiency of the entire company.
• Carrying out the toughest jobs by automatic machine systems increases the safety of warehouse workers.
• Automation of warehouse processes supports the concept of “goods to person”, not “person to goods”, thanks to which it significantly reduces labor costs – especially if the operators previously worked in arduous conditions.
• Automation does not eliminate, but supports the work of people. Warehouse staff will be needed for tasks such as maintenance, repair and machine management.

All the advantages of automation in warehouse logistics lead to one most important benefit: saving money . Warehouse 4.0 is a significant increase in efficiency and the maximum use of potential.

 

FAQ:

Which warehouse processes can be automated?

An investment in warehouse automation is the improvement of numerous logistics processes, incl. organizing the work of warehouse operators, transporting goods, completing and processing orders or controlling the state of warehouse resources.

What are the benefits of automating warehouse processes?

Warehouse 4.0 allows you to expand the scale of the company’s operations, because it increases its efficiency and profits thanks to automation. The warehouse space is used to the maximum, the safety of employees is increased and orders are carried out quickly and without errors. It all brings profits for the entire enterprise.

How does the automation of logistics processes affect employees?

The increase in automatic solutions increases the safety of warehouse employees thanks to the “goods to man” concept. It also introduces the need for people responsible for the maintenance, repair and management of machines as well as programming and operating automatic systems.