Warehouse Automation: Types and Features

This article will explain the types of warehouse automated solutions available and considerations for selecting the right system to match your operational needs.

Introduction to Warehouse Automation

Warehouse automation refers to the use of automated systems and software (with minimal human participation)to perform tasks that were traditionally handled by manual labor. These technologies are designed to replace repetitive, time-consuming tasks for lesser fatigue and injuries of warehouse employees.

Rather than replacing manual tasks, it suggests a more integrated management through software.

Types of Warehouse Automation Systems

Automated solutions vary significantly in their functionality and applications, allowing companies to choose the best option based on their operational needs and budget. Below are the primary types of warehouse automation systems:

  1. Automated Storage and Retrieval Systems (AS/RS)

AS/RS systems are one of the most commonly implemented warehouse automation technologies. These systems are designed to handle inventory storage and retrieval efficiently, reducing the need for manual labor and improving space utilization.

• Mini-Load AS/RS: This type of system handles smaller items and uses mini-load cranes or shuttles to retrieve them from storage. It is ideal for businesses dealing with high inventory volumes but limited space.
• Unit-Load AS/RS: Designed for larger loads, unit-load AS/RS systems are suitable for handling pallets or heavy containers. They offer significant space savings and higher throughput for bulkier items.
• Shuttle Systems: Shuttle-based AS/RS offers high-speed, high-density storage, where automated shuttles move along tracks to retrieve items from storage racks. Shuttles are particularly effective in high-throughput environments.

These systems increase storage density and accuracy while reducing labor costs and errors. Companies can also integrate AS/RS with warehouse management systems (WMS) for real-time inventory control and data tracking.

   2. Goods-to-Person (GTP) Systems

Goods-to-person systems bring items directly to workers, who then pick and pack the products. This system drastically reduces the time workers spend walking through the warehouse, improving efficiency and accuracy.

• Robotic Systems: Robots retrieve products from storage and deliver them to workstations for further processing. This reduces human error and speeds up the picking process.
• Carousels: Horizontal and vertical carousels automatically rotate to deliver items to the operator. This is particularly useful in environments with high picking frequencies or small SKU sizes.

The key advantage of GTP systems is the reduction of travel time within the warehouse, enabling faster order fulfillment with fewer resources.

   3. Autonomous Mobile Robots (AMRs)

AMRs are mobile robots designed to navigate warehouse environments autonomously. Equipped with advanced sensors, cameras, and artificial intelligence, AMRs can safely move around human workers and other obstacles. These systems can handle a variety of tasks, from transporting inventory to performing complex picking operations.

Compared to Automated Guided Vehicles (AGVs), AMRs are more flexible, requiring no fixed infrastructure like magnetic strips or wires. This allows them to adapt quickly to changes in warehouse layout or operations, making them ideal for businesses with fluctuating demands.

   4. Automated Guided Vehicles (AGVs)

AGVs are automated machines that follow pre-defined paths within a warehouse, often using magnetic strips, wires, or sensors for navigation. AGVs are highly reliable and efficient for transporting goods from one point to another in large, simple warehouse setups.

While AGVs are typically less flexible than AMRs, they remain a popular choice for businesses with repetitive material handling needs and less dynamic environments.

   5. Automated Sortation Systems

Automated sortation systems are used to categorize and direct items to their appropriate locations within the warehouse. These systems rely on technologies like sensors, barcode scanners, and RFID tags to ensure accurate sorting.

Common applications of automated sortation systems include:

• Conveyor-Based Sorting: Items move along conveyor belts and are automatically sorted based on pre-programmed criteria.
• Robotic Arm Sorting: Advanced robotic arms equipped with AI can perform complex sorting tasks, especially in environments with high SKU diversity.

Sortation systems are particularly useful in e-commerce warehouses and distribution centers that handle large volumes of small items with varying destinations.

Identifying the Right Time to Automate

A company should consider automating its warehouse when operational inefficiencies become apparent or when scaling growth is hindered by manual processes. Some common indicators include:

• Frequent order errors: If customers are regularly receiving incorrect orders, this could signal a need for automation in the picking and sorting processes.
• High return rates: Automating returns handling through an automated sorting system can streamline the process and reduce the burden on manual labor.
• Space constraints: If the warehouse is running out of storage space, implementing an Automated Storage and Retrieval System (AS/RS) can optimize the available space by increasing storage density.
• Difficulties in staff hiring or high turnover: Automation systems like Autonomous Mobile Robots (AMRs) can help reduce dependency on a large workforce while ensuring operational consistency.
• Increased customer demand: As businesses scale, a higher volume of orders can overwhelm manual systems, leading to longer delivery times. Implementing automation in order picking, packing, and material handling helps meet customer expectations for faster deliveries.

Warehouse Processes That Can Be Automated

Several key warehouse processes can be automated to improve efficiency and reduce manual labor:

   1. Inbound and Receiving

Automating the receiving process speeds up the unloading and sorting of goods. Automated sortation systems and barcode scanning ensure accurate inventory tracking as goods arrive at the warehouse.

   2. Storage

Automated storage solutions, like Automated Storage and Retrieval Systems (AS/RS), allow warehouses to optimize space and increase storage density. These systems can store and retrieve items with precision, reducing the need for large storage spaces.

   3. Picking

Order picking is one of the most labor-intensive tasks in a warehouse. Automating this process with Goods-to-Person (GTP) systems or Pick-to-Light systems increases picking accuracy and speed, while reducing labor costs.

  4. Sorting

Sorting systems can automatically direct goods to the correct storage or shipping areas, reducing manual handling and errors. Automated Sortation Systems use sensors, barcodes, or RFID technology to sort products quickly and accurately.

   5. Packing and Shipping

Automated packing systems, including box erectors and automated label printers, streamline the packaging process. By automating these tasks, warehouses can reduce the time spent on manual packaging and improve shipping times.

Explore the warehouse automated solution Vison offers to merit your business goal.