Warehouse technology - the key to efficient and secure logistics of the future

Estimated reading time: about 8 minutes

TL;DR

• By automating the warehouse, cargo handling times are reduced and errors are reduced.
• A well-implemented WMS improves efficiency and stock visibility.
• Mobile robots and AGVs are the future of storage and material handling.
• Warehouse technologies drive higher profitability and security throughout the supply chain.
• The key to success is a sound needs analysis, integration with ERP and continuous process optimisation.

Table of contents

• Introduction
• What exactly are storage technologies?
• Warehouse automation - a starting point for optimisation
• Digital solutions - software for productivity
• Key trends in storage technology
• Mobile robots and AGVs
• Robotic picking and packing systems
• Shuttle systems, stacker cranes and conveyors
• How do warehouse technologies affect profitability and safety?
• Increased productivity and reduced costs
• Minimising accidents and improving work ergonomics
• Improved stock control and resource planning
• Implementing new warehouse technology - step by step
• Needs analysis stage and design of a tailored solution
• Integration with management systems (ERP, MES)
• Real-time process testing and optimisation
• Examples of the use of modern warehouse technology
• Food and FMCG industry
• E-commerce sector
• Metal and automotive industry
• Warehouse technologies and Michale Automation's offering
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Warehouse technology is one of the most important pillars of modern logistics and supply chain management. Today, automation, digitisation and robotic transport systems are playing an increasingly important role in logistics facilities that focus on efficiency, security and on-time delivery. In times of dynamic market change, investment in innovative warehouse technology can be a competitive advantage for a company - especially when customer demands are increasing and warehousing and picking processes are becoming more complex than ever.

In this article, I explain what warehousing technologies are, how they affect the functioning of the entire company and which specific solutions and trends are worth considering in the coming years. With this knowledge, it will be easier to plan or improve your company's logistics processes.

What exactly are storage technologies?

Warehouse technologies are a set of solutions (hardware and software) that help automate or streamline key warehouse processes. These can range from robotic storage and conveyor systems to advanced warehouse management software (WMS - Warehouse Management System) or intelligent goods identification methods.

Key benefits of implementing modern warehouse technology:
- Increased productivity: stacker cranes, conveyors or mobile robots speed up load handling.
- Higher accuracy and reduction of errors: vision systems and WMS software eliminate errors in order picking.
- Better use of space: automated storage systems allow the layout of racks and storage areas to be planned optimally.
- Worker safety: robotic solutions reduce accidents by taking over repetitive and physically demanding tasks.
- Seamless scalability: storage technologies grow with the business, providing flexibility even when orders increase dramatically.

Warehouse automation - a starting point for optimisation

Automation means implementing equipment and software that can transport, store or pick goods autonomously. These can include robotic pallet stacker cranes for high rack storage, shuttle trucks, as well as pallet and container conveyors. As a result:

• People no longer have to manually transport loads over long distances (which speeds up operations).
• Employees can focus on more valuable tasks, such as quality control or customer service.
• The WMS software oversees the flow of stock and the order sequence.

Automation does not have to mean completely 'excluding' humans from the process. We can implement so-called partial automation - in which case certain zones or activities in the warehouse (e.g. handling full pallets) are subject to robotisation, while others continue to rely on the flexibility of employees. Traditional warehouses are thus evolving into hybrid facilities, where some tasks require human intervention and some are taken over by robots.

Digital solutions - software for productivity

The second pillar of modern warehouse technology - alongside machines and robots - is software. WMS systems take control of:

• Arranging the goods on the racks according to established strategies.
• Order picking sequence and indication of specific locations in the warehouse.
• Co-ordination between workers and machines (e.g. AGVs are informed where and from where to transport a load).
• Real-time monitoring of stock levels to reduce shortages and avoid downtime.

The implementation of such software often also involves integration with an ERP or MES (Manufacturing Execution System) system. Then, management of the flow of goods in the warehouse is linked to production planning or advanced quality control. At Automatyka Michale, when implementing this type of project, the analysis phase is extremely important, allowing the size of the warehouse or type of equipment to be selected according to the customer's specific needs.

Key trends in storage technology

The world of logistics is increasingly daring to draw on solutions based on artificial intelligence, the Industrial Internet of Things (IIoT) or augmented reality. Automated systems in warehouses not only transport goods from point A to point B, but also continuously learn and optimise operations within the facility.

Mobile robots and AGVs

Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) are devices that move around the warehouse using sensors and digital maps. They enable:

• Rapid transport of small loads without operator involvement.
• Collision avoidance through advanced vision systems.
• Easy scalability - another robot can be added as required.

In many companies, AGVs are becoming an alternative to traditional forklift trucks. There are solutions dedicated to high-bay warehouses, the food industry or the pharmaceutical industry.

Robotic picking and packing systems

Pick-and-place robots and automated stations for packaging or labelling complement conveyors and racks filled with goods. Thanks to them:

• Lead times are reduced (which is crucial in e-commerce).
• The risk of mistakenly selecting an item or applying the wrong label is reduced.
• Staff can work in areas that require more flexibility, such as receiving deliveries or quality control.

If you are interested in the development of such packaging robotics solutions, you can take a look at the proposals on offer from Michale Automation. For more on this topic, see
Robotisation of packaging.

Shuttle systems, stacker cranes and conveyors

Efficient storage and internal transport of goods is often realised today with the help of:

• Pallet stacker cranes, which automatically move the load units to the desired aisle or racking section.
• Shuttle systems (shuttle trolleys) that move pallets or containers inside racking channels at high speed.
• Conveyors (belt, chain, roller) - loads prepared for dispatch or further processing move smoothly between storage areas.

The goods-to-person concept works especially well for picking small products that need to be dispatched quickly. The goods then automatically go to an employee who packs the order and puts it away for dispatch.

How do warehouse technologies affect profitability and safety?

The most important objective of implementing innovation in the warehouse is to improve supply chain efficiency. This translates into higher profitability and customer satisfaction and a reduction in errors.

Increased productivity and reduced costs

From the point of view of the COO or CEO, it is the word 'profitability' that is sometimes crucial when deciding to invest in the automation of the storage process. Depending on the scale of the venture, the return on investment (ROI) can occur after just 1.5-2 years. This is because:

• We eliminate unnecessary downtime and shorten transport paths.
• Fewer mistakes are made (e.g. wrong picking), so no time is wasted on corrections.
• Low safety stock (thanks to the precise supervision of the WMS) allows for more efficient management of working capital.

An example of automation in practice could be the robotisation of palletising or packaging processes:
Robotisation of packaging.
Michale Automation is implementing similar solutions in manufacturing plants, among others, to reduce the cost of manual work while maintaining consistent quality.

Minimising accidents and improving work ergonomics

Robotised warehouse technologies delegate to machines those tasks that are:

• Most repetitive (e.g. sorting goods).
• Physically taxing (e.g. lifting heavy cardboard boxes).
• Potentially hazardous (handling chemicals, working at height).

This allows employees to focus on supervision, control or tasks requiring creative thinking. This has a positive impact on the safety of the facility and on the satisfaction and health of the people employed.

Improved stock control and resource planning

Innovative WMS or AI systems can monitor stock levels in real time. Many problems, such as overstocking of seasonal goods, can be nipped in the bud in this way. A properly configured system automatically sends an alert when the number of a particular product falls below a set threshold, which:

• Facilitates forecasting of future orders.
• Reduces the risk of 'empty shelves' and delivery delays.
• It helps to plan human resources rationally (e.g. additional staff for seasonal peaks).

Implementing new warehouse technology - step by step

When planning investments in automation or digitisation of the warehouse, it is worth acting according to a well-thought-out strategy.

Needs analysis stage and design of a tailored solution

The first step is to conduct an audit and determine:

• How is the flow of goods in the warehouse to date?
• How large is the volume of incoming and outgoing cargo?
• Are there areas where humans make the most mistakes when loading or picking?
• Is there a vision for the company's growth - e.g. do we expect to double orders in the next three years?

Based on this information, the layout and degree of automation is designed - not in every case will it be AGVs or fully robotic stacker cranes. Sometimes a smaller, phased upgrade will suffice.

Integration with management systems (ERP, MES)

The next step is to match the warehouse technology with the company's existing software. For example:

• Once a company has an ERP (Enterprise Resource Planning) in place, we aim to ensure that incoming online orders can automatically go into the WMS, triggering picking processes.
• If we are implementing robotic workstations as part of a production line, integration with MES allows data on the availability of raw materials and finished components to be sent directly to the warehouse.

For example, if your company has an automated production line, you may want to consider designing a robot to handle the packaging or stacking of products in cartons. Take a look at
Robotisation of laying.

Real-time process testing and optimisation

Once the new system is up and running, a number of tests should be carried out:

• Check that conveyors or AGVs are operating according to the planned schedule.
• Evaluate how the WMS programme manages picking paths.
• Analyse performance on the basis of KPIs (e.g. picking time per order, documentation error rate).

Often, we find that a slight modification of transport paths or the order of staff tasks saves precious minutes and increases the pace by up to a few per cent.

Examples of the use of modern warehouse technology

Depending on the industry and the specifics of the product range, storage technologies can be adapted in many ways.

Food and FMCG industry

• Automatic stacker cranes and conveyors in cold or freezer rooms where conditions are difficult for people (low temperature).
• AGVs for fast transport of pallets from the production line to the warehouse.
• Pick and place robots for sorting goods by type, use-by date or packaging variant.

E-commerce sector

• The use of shuttle systems so that goods reach the employee picking the order ('goods to person' model).
• Advanced analytics in the WMS to handle the final stages of dispatch and real-time monitoring of stock levels.
• Automated order packaging and labelling systems (especially for high parcel volumes).

Metal and automotive industry

• Pallet stackers handling heavy components such as rims, components, engines.
• Vision systems that monitor component quality prior to shipment.
• Automated welding stations - find out more by visiting
  Robotisation of welding.

Warehouse technologies and Michale Automation's offering

Michale Automatics (also known as Michale Automation) specialises in implementing complex solutions for industry. Although the company is renowned for building machines and production lines and robotics applications (e.g. robotic welding, painting or packaging stations), its team is also experienced in customising warehouse technologies.

Practical support includes:

• Analysis of goods flow and design of storage areas.
• Selection of automatic storage equipment (stacker cranes, conveyors, shuttle systems).
• Integration with existing production, including synchronisation of robots and stations with vision or ERP systems.
• Service and maintenance of robotic workstations (for details, see the
  Service and maintenance stands).

It is worth mentioning that Automatika Michale is an official distributor of SIASUN robots, which allows it to offer some of the most innovative solutions in the field of line and warehouse process robotisation.

Practical conclusions and recommendations

- Start with a sound analysis: not every company needs a fully automated warehouse. Sometimes conveyors and a simple WMS are enough to significantly improve the workflow.
- Invest in software: WMS tools integrated with ERP are often the cheapest and fastest way to reduce errors and improve stock visibility.
- Consider flexible robotisation: AMR systems or AGVs can be scaled up as orders increase, so you do not need to invest in a large fleet of machines straight away.
- Monitor key indicators (KPIs): only then will you see the real impact of modern solutions on productivity and safety.
- Ensure the competence of the team: appropriate training allows employees to better understand new technologies and work with them more effectively.

Summary

Warehouse technology is the future of logistics - but successful implementation requires a good plan. Innovations such as robotic stacker cranes, AGVs, vision systems or WMS software have real potential to speed up warehouse operations, reduce costs and improve safety.

Whether you're running a small manufacturing company or managing an expansive logistics centre in the e-commerce industry, the right warehousing technologies can become a lever for further business growth. If you are wondering how to get started or which solutions are best suited to your situation, consider contacting the experts.

I would also encourage you to check out Michale Automation, which has a skilled team of engineers and integrators ready to assess the needs of your line or warehouse. For more information on services and robotics:
Robotisation services.

Want to find out more or tailor a system to your needs? Browse through the articles on the company's blog, take advantage of the opportunity to make enquiries or check out the service and maintenance of robotic solutions in practice. Thoughtful implementation of warehouse technology will result in faster processes, higher service quality and greater safety - features that are absolutely essential to stand out in a dynamic market and meet growing customer expectations.

FAQ

How long does it take to implement automation in a warehouse?
Implementation time depends on the size of the facility, the complexity of the processes and the need to integrate with existing systems. For simple solutions it can be a few weeks, while extensive projects can take up to several months.

Is warehouse automation completely replacing human labour?
Not always. In many cases, partial automation is used, with machines taking over repetitive and physically demanding tasks. Employees, on the other hand, take care of supervision, customer service or more creative activities.

Does warehouse robotisation pay off for smaller operations?
Yes. Thanks to advances in technology, the cost of purchasing and maintaining robots and automation systems is falling. Smaller companies can implement flexible, modular solutions and scale them up as orders increase.

What are the benefits of integrating WMS with ERP?
The integration of the warehouse management system (WMS) with ERP ensures a consistent flow of information throughout the company. Orders, inventory and the picking process are all visible in one system, speeding up response times and avoiding costly errors in the supply chain.