Warehouse Automation is evolving with the evolution of science and technology and the advent of the Fifth Industrial Revolution. Industry 5.0 has also provided state-of-the-art technologies from Robotics & Internet of Everything (IOE) to Smart Packaging to Nano-Sensors. Automation in warehousing and logistics has increased efficiency, reduced errors, and improved the overall productivity of the food processing industries. Warehousing automation streamlines the repetitive activities in the warehouses and cold storage to ensure efficient processing with optimum time.
Warehouse Automation: New Developments and Initiatives Amid Industry 5.0
The evolving technological landscape with rapid development in science and technology has changed the warehousing sector. There are various new developments across different segments. It includes:
Picking Automation
The process of picking is repetitive and time-consuming. To counter it, Modular shelving systems are combined with warehouse robotics. It helps to automate the picking process. It also eliminated any chances of human error from the system. The automation in the picking process is crucial for perishable food articles in the food system.
Barcode Labels and Scanning Automation
The tracking of articles in warehouses relies heavily on documentation. This is because of the regular movement of food articles in and out of the facility. To speed up the picking and stocking process, and manage inventory automation has emerged as a better alternative. Automatic identification of barcode labels, rack labels, warehouse signs, and hardware can speed up the process. Barcode labels combined with the right software and scanning technology can eliminate errors and drastically speed up documentation processes.
Automated Vehicles
The movement of items inside the warehouses needs different equipment. Previously, forklifts and pallet jacks were the traditional equipment used to move goods throughout a warehouse facility. Automation has helped to develop self-guided forklifts and pallet carts, which are collectively known as Automated Guided Vehicles (AGVs). These automated vehicles require human operators. These vehicles follow digital paths through the facility to load and unload pallets, boxes, and other containers.
Inventory Automation
According to a report titled “From Cost Center to Growth Center: Warehousing, 2018,” by Motorola, 41% of warehouse facilities were still reliant on pen-and-paper methods for cycle counts. It results in errors related to data entry and transcription, as well as inconsistent inventory processing. In some cases, disruptions are caused to overall operations. Automating inventory management processes helps to do away with these limitations.
Back-Office Automation
The real-time data in the Warehouse Management System (WMS) is crucial for warehouse management. The inaccurate inventory counts cause supply chain disruptions and other inaccuracies. The outdated, manual processes lead to errors and delays. Out-of-stock conditions can lead to dissatisfied partners and customers. It can damage brand reputation. Further, excess inventory that spends too much time sitting idle on racks and shelves eats at bottom-line storage and operational costs. During the downtime, lost productivity and more serious errors occur hindering growth or actively lowering profits of the warehouses. Automation can do away with these limitations of warehouse management.
Warehouse Automation: Development of State of Art Automation Solutions for Warehouses
The rapid evolution of technology in warehousing has led to the development of the following state of art technologies. These are:
Goods-to-Person Technologies (GTP)
GTP technologies bring items to the worker rather than requiring workers to travel to the items that need to be picked. Warehouses with GTP systems retrieve orders from a central database like an ERP, and then automated equipment locates the items in the warehouse and moves them to the picking area. The throughput rates of GTP far exceed those in manual warehouses. As a result, companies that leverage GTP technologies can reduce their operating and order fulfillment costs and improve service levels.
Producer Companies
FORTNA, Exotec, Honeywell, Daifuku, Mecalux, and SRSI are some of the companies that provide Goods-to-Person (GTP) technologies.
Automated Storage and Retrieval Systems (AS/RS)
These are one of the types of GTP technology. It automatically brings goods out and then places them back into storage. Warehouse managers pair AS/RS systems with a warehouse software system that manages the process and assists warehouse workers in processing orders.
Producer Companies
Kardex India, Deliecn, Addverb, and Zebra Technologies are some of the companies providing such solutions.
Pick-To-Light Systems
In this system, warehouse operators scan barcodes as LED displays illuminate to guide them to the correct storage location. It can also indicate the automatic pickers and how many items should be picked. The operator then places the picked items in containers and confirms task completion by pressing a button near the display. The displays continue to illuminate each operator’s work zone and direct them to the next picking location.
Producer Companies
AIOI-Systems, Banner Engineering, Panasonic, Omron, and Sick AG are major providers of hardware such as sensor technology. Daifuku, Murata Machinery, SSI Schaefer, and Dematic are major system integrators and solution providers.
Autonomous Mobile Robots
These systems are popular in the e-commerce segment. They help in fulfillment situations to address their high-volume, high-labor requirements. AMR works with warehouse workers by moving through the warehouse floor. These systems work like manual pickers until their totes are full and then transport them to the pack station. There are other AMRs that use vacuums and trays to pick boxes and totes from warehouse shelves. After this process, it loads them onto a mobile robotic cart.
Producer Companies
MiR (Mobile Industrial Robots), OTTO by Rockwell Automation, Omron, Geek+, KUKA, and ABB are the main manufacturers of such technologies.
Market Analysis: State of Warehouse Automation System in India
According to the Grand View Research, the global warehouse automation market size was estimated at USD 19.23 billion in 2023. The agency is projected to grow at a CAGR of 18.7% from 2024 to 2030.
Drivers of the Warehouse Automation Market
The emerging technological trends such as the increasing use of Cobots, AMRs, and AI are the main drivers of the automation market.
Increasing Use of Cobots and AMRs
The adoption of robotic systems across the warehousing landscape is the main driver of the warehouse automation market. Autonomous Mobile Robots (AMRs) and Collaborative Robots (cobots) have gained importance for tasks like picking, packing, and material handling.
AI and ML Integration
The warehouse managers are using the integration of Artificial Intelligence (AI) and Machine Learning (ML). These technologies enable more sophisticated data analysis, predictive maintenance, and optimized decision-making processes.
Rise of E-Commerce and Quick Commerce
The surge in E-Commerce and Quick Commerce is a major driver of warehouse automation. To meet the demand of online shoppers for faster and more accurate order fulfillment E-commerce giants like Amazon and Flipkart rely on these automation technologies in the warehouse.
International Regulations in the Automated Warehousing Sector
There are various global regulations that bind the warehouse automation market. These standards have their own terms of safety standards and labor laws. These technologies must comply with occupational health and safety regulations and ensure that automated systems do not pose risks to human workers.
European Union
In the European Union, the machinery used in warehouses must comply with the Machinery Directive, which sets out essential health and safety requirements.
USA
In the U.S., the Occupational Safety and Health Administration (OSHA) provides guidelines for the safe use of robotic systems in workplaces.
Other Regulations
Data privacy and cybersecurity are also critical regulatory concerns. These systems aim to safeguard warehouses which are connected through IoT devices and cloud-based management systems. Further, regulations like the General Data Protection Regulation (GDPR) in the EU and the California Consumer Privacy Act (CCPA) in the U.S. require companies to implement stringent data protection measures.
Conclusion
The rapid development of the e-commerce market especially after the evolution of quick commerce has transformed the warehousing landscape. Hence, there has been a large-scale integration of warehousing services with modern technologies. These technologies have made the warehousing management more efficient and accurate. It has also done away the human errors in warehouse management and supply chain.