Warehouse automation risks to avoid

03-04-2022 455

Many risks can be mitigated early in the process, with the right partner and with a robust design process.

Mục lục
Automation can work wonders. It reduces costs, increases throughput, limits errors, and increases safety. Automation costs are falling while the efficiency of computer, vision and scanning systems is improving. Automation helps you reduce repetitive actions. Automation comes in many forms, from picking systems like light picking to automated conveyors to person-to-person freight systems and much more.
 

What is warehouse automation?


Warehouse automation is the process of automating the movement of inventory in, in, and out of warehouses for customers with minimal human assistance. As part of an automation project, a business can eliminate labor-intensive tasks associated with repetitive physical work as well as manual data entry and analysis.
 
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How does warehouse automation work?


Warehouse automation works by using software and technology such as robots and sensors to automate tasks. These products work in synergy with existing tools such as inventory management software.

Warehouse automation helps ensure that the business-critical operations in your facility meet the needs of your customers. It starts with a warehouse management system (WMS) that automates manual processes and collects data, controls inventory, and supports data analytics. These systems integrate with other solutions to efficiently manage and automate tasks across different business and supply chain functions.
 

Warehouse automation risks to avoid


For all these benefits, you want to understand potential problems with any automation project in advance so you can avoid them moving forward.
 

1 - You automate a poor process


It is not possible to automate a broken system or you just make mistakes faster. The point is that you have to set adequate goals. You must understand how more throughput in picking can affect packaging and shipping. You must have a thorough understanding of the entire process before implementing any automated solution.
 

2 - You automate without growth planning


Pre-configured select modules for future growth. The up-front costs of building them up so that another level can be added later is pretty insignificant, but the scalability is invaluable.

- Space: Your system can be expanded up, out or otherwise

- Throughput: It is much easier to build a faster system without using the current rate than to increase the speed in the future. If you can increase the flow rate at will, you can also accommodate seasonal spikes or sudden changes in order volume. Your system must be faster than you need daily. The cost is quite small but the acceleration is invaluable.

- Extra: If you anticipate future growth, can your building handle more work cells? Can you add conveyors or overhead robots in critical areas that will help you meet demand?
 

3 - You automate at the wrong time


One thing smart companies do is weigh the need for full automation versus partial automation. Partial automation is smart for many types of operations, where ROI may not be possible for a fully automated system. One of the places we often see partial automation is at the end of the line, where machines can replace human labor using automation such as stackers or robots.

If you're automating the workspace or stacking operations, be aware of how upstream or downstream work can be affected. Does it create congestion elsewhere? If you add a higher speed conveyor during picking, can your packaging process handle the output? All can be adjusted with prior consideration.
 

4 - You do not include your floor staff and middle management in this process


Automation almost always depends on employee input. Success isn't just about well-designed equipment and software. Like many other things in life, it's about people. You may need to change your organization. You may need to consult with departments that are not normally involved in the process.

This is key for middle managers and floor leaders who can turn the tide in your favor as the project progresses.

You will almost certainly need to retrain workers whose jobs will be completely impacted by the new system. That training has to happen, organized before you implement the system, or after, when you'll have less control, more chaos, and more pressure. Successful implementations often focus on training, retraining, and consulting with the employees who will be using the device. You can't train too much if you want a successful launch.

Don't forget how difficult change can be for many people. Work to help them understand the new way of doing things and how it will help them succeed. Part of it is training on how to use the system, but part of it is education about why the system makes things better for everyone. People almost always respond better if they are asked to contribute. Most well-designed automation is simpler for the people who operate it, but change is always difficult.
 

5 - You don't take your base environment into account


The wrong operating environment can completely paralyze automatic equipment. Humidity, heat, chemicals, oil, dust and airborne debris can reduce the operational life of automated systems or completely paralyze them in extreme situations. If you are operating a typical dry or temperature controlled warehouse that does not require rinsing or sanitizing, you should still evaluate the conditions where expensive conveyors or robots are installed. Dust from everyday cartons can accumulate on exposed machinery. Good maintenance procedures can help with this aspect.

Most conveyors and other equipment can be manufactured to operate in wet or washout conditions such as those you would typically find in food processing, pharmaceutical or other clean areas.

Also, consider the noise level. Many modern conveyors produce significantly less noise, but if your machinery is loud and noisy, it can affect your employees. Ergonomic effects need to be evaluated as you plan your system.
 

6 - You do not anticipate potential difficulties when starting


When you make major changes to your operations, even the best plans can go wrong. If you are aware of the possibilities and take steps to ensure your operations can withstand service disruptions when jagged lines are handled, you will reduce your risk. The process of planning for disruptions can even help you uncover weaknesses in the plan. When these interruptions occur, they are short-term, but you can still prepare for them with good planning.

Profits are real, but they may not be there from day one. If you and your automation partners are already done with their work, the adjustment time will be short and painless.
 

Ending


Many risks can be mitigated early in the process, with the right partner and with a robust design process. Automated systems are subject to change. They make your company faster, more precise and more flexible. Yes, there are risks, but you can minimize them with careful forethought and smart design.

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