By Ryan Thompson, Senior Specialist in Industry 4.0, and Brad Prizer, Industrial Engineer and Warehouse Specialist, CRBs
As labor shortages linger, many manufacturers are looking for ways to make the most of their employees’ time and skill sets, which in some cases means deploying partial or full warehouse automation. But how do you get there, and which material handling (MH) and storage solutions are right for your business? Experts from global provider CRB provide tips to help you assess and plan your warehouse automation strategy.
What are the benefits of warehouse automation?
Ryan Thompson: Best-in-class factories can increase throughput, reduce errors, and keep warehouses running without human intervention. Automated warehouses integrated with a warehouse management system (WMS) can get raw materials where and when they are needed, quickly and accurately. This helps reduce manufacturing downtime caused by inconsistent or ill-timed movement of materials from within the facility. Similarly, finished goods can be moved in and out of warehouses seamlessly, without the need for human touchpoints (no need for constant pages of loudspeakers or radio calls). Integration with quality systems also ensures that finished products are ready for release before they are shipped to customers, eliminating errors that can lead to logistical (or recall) problems. . A well-planned automated warehouse also has multiple safety benefits as it reduces the chance of operator injury and collision during picking/storage and transportation operations.
Is an automated solution right for everyone? When does it make sense?
Brad Pryger: Processes should be analyzed to determine the correct level of automation. To understand the process metrics that drive the feasibility of automation adoption, it is essential to perform operational analysis. Also, if your current processes are not well defined and you have inventory and quality issues, these issues can be exacerbated by automation.
Ryan Thompson: Depending on the factory throughput, there may not even be an appropriate level of automation. As Brad mentioned, the added complexity of automation can cause even more headaches if the process isn’t well defined.
Are there any facility types or layouts that are inherently suitable for automation? What are the facility layout challenges when incorporating automation?
Brad Pryger: Auto-move is good when the travel distance is too long. Whether static automation, such as conveyors, or dynamic automation, such as automated guided vehicles (AGVs) and autonomous mobile robots (AMRs), more space is needed, but the space is compensated for by increased throughput. increase.
Ryan Thompson: When floor space (or surface area) is the limiting factor, taller warehouses with automated storage and retrieval systems (ASRS) often help. This allows for higher racking and tighter spaces between aisles for more storage per square foot.
If the AGV goes outside the warehouse for additional material movement, it is important to investigate and understand the routes, material flow and frequency. Poor planning can cause one row of robot lanes to become a bottleneck for the entire factory.
Are there any products better suited for automation solutions?
Brad Pryger: In addition to increased productivity, automating the storage of products that require refrigerated or frozen storage and the movement of materials offers many potential benefits. Eliminating the need for operators to enter sub-zero temperatures reduces the potential for safety issues. Automated solutions also have the potential to reduce the footprint/volume of storage areas, which can result in significant cost/energy savings when considering the room adjustments required for these spaces.
What are the biggest mistakes/oversights you see in your automation strategy?
Ryan Thompson: For me, it’s an island of automation, not integrating the warehouse with other operations. The ASRS system is fine by itself, but it still requires a lot of human input to request anything from the system.
What questions should the project team ask early in the planning stage?
Brad Pryger: Understanding current processes is critical to determining the feasibility of automated solutions. Does your current process/layout lend itself to automation? Do you have enough throughput? Do you have the right systems/software in place? Are you tracking the metrics (and the right ones)? what is it?
Ryan Thompson: The most important thing is to understand the big picture. If your business is running well, what is your raw material and finished product throughput? What if your volume increases by 25%? I think it’s important to consider efficiency studies. In addition, planning your enterprise resource planning (ERP) and integration requirements with your manufacturing execution system (MES) will help you understand the expected benefits to be achieved that can be quantified and measured against your investment costs. .
Brad is an Industrial Engineer at CRB, specializing in process improvement for many industries, from manufacturing and healthcare to business processes. His solutions are data-driven to optimize efficiency, reduce waste, and achieve business goals, regardless of industry. With 10 years of experience, he is proficient in both process improvement and project management. As a certified PMP. In addition to process improvement, Brad also specializes in warehouse operations and layout design. He appropriately sizes warehouse operations to meet his business needs while optimizing the flow of materials, personnel and traffic. He utilizes computer modeling and his technology to help clients operate their facilities more efficiently, reduce costs, increase throughput and improve quality.
Ryan brings over 17 years of experience in successfully leading companies and projects through digital transformation. He leverages a unique combination of technical expertise, strong leadership and clear communication to drive meaningful and scalable Industry 4.0 strategies and roadmaps. Ryan pursues continuous process improvement through tools, technology and innovation, and puts ROI first in order to deliver sustainable solutions for the big picture. He believes the purpose of Industry 4.0 is to do more with less.