Automation itself is not a new concept in logistics. In recent years, many technologies have entered the warehouse floor and are taking over an increasing portion of warehouse operations, albeit often in isolation. One example is the deployment of enclosed automated warehouse towers with lift-shift shelving designed for storing and picking particularly smaller parts, known as Kardex.
Other examples are automated conveying and sorting lines, semi and fully automatic stackers (unmanned unmanned trucks) or entire transport (warehouse) trains that are guided around the warehouse by magnetic tape in the floor or, more recently, by laser navigation. These automated solutions involve investments in the order of units to tens of millions of crowns and are still not profitable for many smaller and medium-sized customers. What is now worthwhile for virtually everyone (even for warehouses with only a few warehouse staff) is the move from paper and pencil to mobile terminal (PDA) control. These, in conjunction with even a simpler WMS, can make warehouse work much more efficient.
Automation in warehouses affects entire processes, most of all dispatch. Here, the emphasis is on time accuracy (unloading or loading of materials and shipments within precisely defined time windows) or planning and grouping orders into shipments according to the physical dimensions of the package so that the capacity of containers and vehicles is maximally filled and, conversely, transport distances are minimised. This not only benefits the customer, but also the carrier, who can better plan their capacity based on online shipping data.
Analysis of big data can lead to more accurate estimation of the time of arrival of the vehicle at the warehouse according to the current situation (shipment movement, weather, traffic situation, etc.), and therefore to more accurate planning of warehouse operations at the reception. For example, social network analysis helps to estimate future customer demand, which is necessary for modelling goods flows and more accurately supplying points close to consumption (stores, distribution centres); at warehouses, it helps to optimise stock – goods that are expected to move more are moved to closer positions.
Digital warehouse map
Thanks to the range of technologies available today, it is possible to track the overall movement in the warehouse and digitise the online location of all elements (warehouse workers, handling equipment, transport packaging and materials) into a so-called digital warehouse map. This provides a very valuable basis for further system decision-making – it is possible to react immediately by changing the tasks of individual workers so that there are no conflicts or delays in their performance and at the same time warehousemen and equipment are used to the maximum without unnecessary (empty) errands and trips. Based on this online data, it is also possible to optimize the placement of shipping containers and assortments in the warehouse and dynamically change system parameters to optimize warehouse processes. The collected data can also be used advantageously in business intelligence tools for evaluating the work of warehouse staff.
Wi-fi, Bluetooth
The most commonly used technology for online localization of items in stock is the existing wi-fi network, but more accurate results can be achieved using the new Bluetooth Low Energy (BLE) communication standard, which is suitable for connecting readers (signal receivers – so-called anchors) and chips attached to tracked objects. The chips are powered by an ordinary button cell battery, the capacity of which is sufficient for several years of operation. In this way, stock elements can be located with an accuracy of tens of centimetres. The technology for localization inside warehouses in particular holds high potential for the future. They can significantly help identify bottlenecks, reduce operating costs and reduce worker errors.