From robots to automated processes, various types of warehouse automation technologies can significantly boost productivity.
Manual processes often come with warehouse challenges like high operational costs, costly human errors, and longer processing times. 11 different types of warehouse automation are designed to address these issues.
A study predicts that by 2025, warehouse automation and robotics will increase productivity by 25% to 70% and reduce operating costs by 20% to 40%.
This blog explores the eight types of warehouse automation that enhance warehouse productivity. But first, let’s understand what warehouse automation is.
What is Warehouse Automation?
Automation is essential for many parts of a business, especially for handling complex tasks. In a warehouse, which is the core of daily inventory management, using modern technology can automate these tasks, improve profits, and keep the business competitive.
With so many technologies available, business owners need to choose the ones that boost efficiency, simplify operations, lower costs, and make sure goods and materials move smoothly. Let’s look at the types of automation and some common technologies used to automate warehouse tasks.
11 Types of Warehouse Automation
We’ve listed the different types of warehouse automation systems, have a look!
1.Warehouse Management Systems
Warehouse management systems (WMS) are software applications designed to streamline daily warehouse operations. They allow you to manage, monitor, and optimize key warehouse functions, including:
- Tracking inventory
- Directing picking, packing, and shipping activities
- Coordinating material handling equipment
The main goal of a WMS is to ensure that warehouse materials move in the most cost-effective and efficient way from the moment they enter until they leave.
Benefits of using warehouse management systems include:
- Lower labor costs: A WMS identifies the best workers for key tasks and can automatically generate schedules, reducing labor allocation guesswork.
- Improved inventory management: Real-time tracking helps avoid backorders and supply issues.
- Better use of space: WMS can optimize storage by determining the best locations for inventory.
Major WMS vendors include:
- SAP
- Oracle NetSuite
- IBM
- Microsoft Dynamics
2.Collaborative Robots
Collaborative robots, or “cobots,” are designed to work alongside human workers. They help reduce errors, increase efficiency, and free up time for other tasks.
A study by Darex found that cobots increase efficiency by 30%! Cobots are used in various warehouse operations such as packing, picking, palletizing, and inspecting.
Major cobot vendors include:
- Universal Robots
- Techman Robot
- Locus Robotics
3.Automated Guided Vehicles & Autonomous Mobile Robots
Automated guided vehicles (AGVs) are self-guided vehicles that move across a warehouse with an onboard operator. In contrast, autonomous mobile robots (AMRs) move automatically without an onboard operator, using sensors to navigate their environment.
Benefits of AGVs and AMRs include:
- Increased productivity and efficiency: They set the pace for employees and keep them on task.
- Reduced labor: They handle navigation, reducing the amount of labor needed for material handling.
- Less human error: Better accuracy and fewer losses in material handling.
- Better scalability: Start with a few units and expand as needed.
- Improved safety: Sensors and cameras help avoid collisions.
Major AGV and AMR manufacturers include:
- Bastian Solutions
- Agilox
- America In Motion
- Balyo
4.Automated Storage and Retrieval Systems
Automated storage and retrieval systems (AS/RS) manage the storage and retrieval of cargo within a warehouse. These systems follow set routes to handle materials automatically, reducing the need for manual labor.
AS/RS systems come in various configurations like cranes, shuttles, vertical lift modules (VLMs), and carousels.
Benefits include:
- Lower labor costs: AS/RS systems reduce the need for manual labor in picking and placing materials.
- Improved accuracy: Elimination of manual picking processes increases accuracy.
- Maximized space: High storage density with compact storage and better use of vertical space.
Major AS/RS manufacturers include:
- Kardex Storage Systems
- Conveyco
- Bastian Solutions
5.Wearables
Wearable technology, like augmented reality smart glasses, finger-trigger gloves, and GPS-tracking bracelets, enhances warehouse operations. These devices, worn by operators, provide real-time information to speed up operations without distracting from tasks.
Benefits of wearables include:
- Less distraction: Eliminates the need for cumbersome paperwork or electronics.
- Better efficiency: Reduces the number of touchpoints needed for tasks.
- Lower costs: Enables workers to do more in less time, allowing for better labor allocation.
Major wearable manufacturers include:
- Smart Gladiator
- Vuzix
- Koamtac
- ProGlove
6.Predictive Maintenance
Predictive maintenance involves monitoring equipment to detect potential issues before they cause failures. This method uses sensors like acoustic monitoring, infrared thermography, and vibration analysis to schedule necessary maintenance.
Benefits include:
- Less downtime: Alerts managers to issues before they cause failures, potentially reducing failures by up to 90%.
- Improved safety: Prevents equipment failures that could lead to safety issues.
- Increased equipment lifespan: Early alerts help address problems before they worsen.
Major providers include:
- SAP
- Microsoft Azure
- Siemens
- MobilityWork
7.Fleet Management Systems
Fleet management involves monitoring and managing an organization’s vehicles to maximize productivity and efficiency while reducing costs. Fleet management software and telematics gather data from devices on vehicles to improve operations.
For warehouses, fleet management systems often track forklifts and offer benefits like:
- Activity tracking: GPS locators help monitor forklifts and operators within warehouses.
- Equipment protection: Security alerts provide real-time updates and enable instant follow-ups.
- Workflow optimization: Tracks route efficiency and suggests improvements.
- Maintenance management: Tracks usage hours to schedule maintenance.
Fleet management services can be obtained from vendors like Unified Fleet Solutions and Toyota’s MyFleet.
8.Pick-to-Light and Put-to-Light Systems
Pick-to-light systems use light devices to guide workers on where to pull items from storage. Workers scan a barcode, and lights on racking indicate which items to pick. Put-to-light systems work in the opposite direction, guiding where to place items in storage.
Benefits include:
- Increased productivity: Can boost productivity by 30 to 50%.
- Improved accuracy: Reduces mistakes by eliminating manual location determination.
- Reduced training costs: Simple and intuitive systems can be learned quickly.
Major vendors include:
- Lightning Pick
- Storage Solutions
- Bastian Solutions.
9.Voice Picking
Voice picking uses verbal commands to help warehouse workers fulfill orders. Integrated with WMS or ERP software, the system conveys order details through a headset. Workers are guided to pick items and can confirm locations and quantities by speaking.
Benefits include:
- Improved accuracy: Reduces manual labor and improves order accuracy.
- Better productivity: Focuses workers solely on picking tasks.
- Improved safety: Hands-free operation reduces distractions and accidents.
Leading manufacturers include The Numina Group and Panasonic Mobile Solutions.
10.Automated Sortation Systems
Automated sortation systems remove manual labor from identifying and diverting materials on a conveyor. These systems use technologies like barcode scanners and sensors to sort items.
Benefits include:
- Less reliance on labor: Helps manage small labor pools.
- Faster processing: Works faster and longer than human labor.
- Better accuracy: Reduces errors and improves customer satisfaction.
Major vendors include:
- Toyota
- Dematic
- BEUMER Group
11.Industrial Internet of Things (IIoT)
The Industrial Internet of Things (IIoT) connects devices in an industrial setting, including WMS, predictive maintenance software, and AGVs. This network improves communication, coordination, and efficiency.
Benefits include:
- Better efficiency and productivity: Identifies gaps in operations.
- Lower costs: Reduces issues like unplanned downtime.
- Better decision-making: Provides data for informed resource allocation.
IIoT solutions can be obtained from:
- Particle
- Kalypso
- DMC
There you have it, the 11 different types of warehouse automation systems that can act as an advantage in your warehouse!
FAQ: 11 Types of Warehouse Automation:
Is RFID a type of warehouse automation system?
RFID (Radio Frequency Identification) is a technology used in warehouse automation for tracking and managing inventory via wireless data transmission, enhancing efficiency and accuracy.
What are automated sortation systems?
Automated sortation systems use technologies like barcode scanners and conveyors to automatically sort items into designated locations, reducing manual labor and improving processing speed and accuracy.
What are automated guided vehicles?
Automated guided vehicles (AGVs) are self-guided machines that transport materials within a warehouse using predefined paths or sensors, reducing manual handling and increasing efficiency.
Conclusion
Adopting different types of warehouse automation systems can transform efficiency, reduce costs, and boost productivity. If you’re looking to integrate technologies like those, consider browsing through Qodenext! We have innovations to enhance your warehouse management and achieve remarkable results!
