In this article, we’ll explore the steps involved in moving from manual management to a fully automated system, the undeniable benefits of this transformation, and how businesses of all sizes can adapt and thrive in this new environment. From mechanized order picking to dark warehouses, discover how automation is becoming the new norm in the world of e-commerce.
In today’s e-commerce landscape,warehouse automation is no longer an option, but a necessity. Faced with the meteoric rise of e-commerce, supply chain managers are faced with a series of daunting challenges. The multiplication of product references, increasing order volumes, pressure to reduce delivery times and recruitment challenges are forcing companies to rethink their logistics automation from A to Z.
To remain competitive in an increasingly saturated environment, it is imperative to implement solutions that ensure service quality and efficiency, even during peak periods. In particular, intralogistics automation – the automation of operations inside the warehouse – offers significant advantages in terms of inventory management and flow optimization.
So how do you take this crucial step? What steps need to be taken to transform a still largely manual warehouse management system into an automated, agile, high-performance one?
What is order-picking mechanization?
Order-picking mechanization is the process of automating the various stages of picking, sorting and dispatching items in a warehouse.
This automation is essential to the operation of a logistics platform, as it replaces manual tasks with integrated machines and systems that ensure greater efficiency, reduce errors and speed up operations.
This system often integrates scanners, conveyors, robots and information management systems to optimize the supply chain.
Why automate a warehouse?
Warehouse automation has become a major issue in the world of logistics and warehousing, offering significant advantages:
- Increased efficiency: machines don’t tire, and work at a constant speed. This means more orders can be processed in less time.
- Error reduction: A machine programmed to perform these tasks with precision eliminates the potential for error, increasing the reliability of your operations.
- Operating costs: Although the initial investment may be high, operating costs are often reduced over the long term.
- Reliable inventory management: you can monitor stock levels in real time, enabling better planning and avoiding the costs associated with out-of-stock situations or overstocking.
How do you automate a warehouse?
Warehouse automation has become a priority for many companies seeking to optimize their logistics operations, increase efficiency and reduce costs. In this context, it is essential to understand the various stages involved in this process.
Feasibility study and definition of requirements
Before plunging into the world of automation, every company must first conduct a feasibility study and clearly define its needs. This will help guide decisions towards the most appropriate solutions.
Choosing a WMS (Warehouse Management System)
Once this stage has been completed, the company needs a warehouse management system to run the facility. This IT system is the orchestra conductor of the warehouse, controlling all aspects from goods receipt to dispatch, including storage and order preparation. It also monitors quality standards and ensures product traceability.
However, if the company wishes to integrate warehouse management with other corporate functions such as accounting, human resources or purchasing, an ERP (Enterprise Resources Planning) will need to be connected to the WMS. Indeed, while the WMS focuses on the optimal management of warehouses and goods flows, the ERP offers a more global vision, encompassing various operational areas of the company. Ultimately, it’s not a question of choosing between an ERP or a WMS, as they complement each other.
Equipment and technologies
Warehouse automation requires a variety of equipment, which can be divided into two main categories:
- Fixed equipment : This includes sorters, stacker cranes, conveyors, etc.
- Mobile equipment: automated guided vehicles (AGVs), forklifts, drones, etc.
Additional technologies such as voice recognition or radio frequency can also be integrated to facilitate communication with operators.
Storage automation
Depending on your needs, you can choose between different levels of storage automation, ranging from semi-automatic solutions such as the Pallet Shuttle to more complex systems such as automatic three-directional stacker cranes. These solutions are adaptive and can be implemented according to the volume of goods to be handled.
Automated picking and internal transport
For companies with intensive picking operations, solutions such as robotic arms or automated bin storage systems can be extremely useful. In addition, intelligent internal transport solutions, such as pallet and bin conveyors, AGVs and mobile robots (AMRs), can automate the flow of goods within the warehouse.
Automated packing (Warehouse Control System)
Depending on the nature and complexity of your operations, packing automation offers a wide range of options. Ranging from semi-automatic systems, such as assisted packing stations, to fully integrated solutions with robots capable of packing, labeling and sorting goods. These technologies are scalable, and can be optimized according to the speed required and the variety of products to be packed.
Dark warehouses
In a scenario of total automation, we speak of “Dark Warehouses”, where all processes are automated, eliminating the need for staff and lighting in warehouses, maximizing productivity and reducing costs.
Automated loading and unloading
Automated systems can also be used for loading and unloading trucks, speeding up the goods-in and goods-out process.
Which missions should be automated?
The complete automation of a warehouse can require a significant financial investment. It is therefore crucial to study profitability and return on investment before committing to such a project. A feasibility study, carried out as the first step in an automation project, can help identify which operations should be prioritized for automation. Generally speaking, these are the operations most likely to generate errors when handled manually.
- Goods receiving: Conveyors in the receiving area can automate the flow of goods as they are unloaded.
- Warehousing: Use pallet stackers, mini-loaders, sorters, mini-shuttles and self-guided vehicles to efficiently move and store goods in the warehouse.
- Order picking: Various techniques can be used, such as voice-picking, put-to-light or pick-to-light.
- Order packaging (WCS): Machines can be used to fill cartons, seal and wrap pallets.
Amazon, the pioneer in warehouse automation
Automation is not just a futuristic concept; it is already a reality in a number of sectors, including e-commerce, retail, textiles and pharmaceuticals. The case of Amazon, often cited as the most innovative company in this field, merits a closer look.
In 2021, Amazon inaugurated its second automated site near Metz. To give you an idea of the scale of this investment in technology, let’s consider a few figures. The warehouse covers an impressive 182,000 m² and is spread over 4 levels, 3 of which are fully automated. The site uses a variety of technologies to speed up the order picking and dispatch process, including real-time inventory management, robots for picking and packing, and advanced systems for tracking and delivery.
Amazon’s example perfectly illustrates how automation can transform a traditional warehouse into a model of performance and efficiency. Of course, not every company has Amazon’s resources, but the point here is that automation, even on a smaller scale, can deliver significant gains in efficiency, accuracy and cost.
The idea is not to replicate exactly what Amazon is doing, but to draw inspiration from these examples to see how your company can also benefit from automation. Solutions exist to adapt this technology to companies of all sizes, including small and medium-sized businesses looking to optimize their supply chain.
So, whether you’re an SME in the textile sector or a large pharmaceutical company, automation has something to offer to improve your operations and, by extension, your success in the marketplace.
Optimize your growth: Automate your warehouse!
Optimizing warehouse operations is crucial to meeting customer requirements while controlling costs. With this in mind, Shippingbo is the ideal solution for modernizing, automating and streamlining warehouse operations. From inventory management to state-of-the-art order-picking tools, we offer you an in-depth view of our suite of services.
Stock management
Shippingbo helps you know how many products to order and when, while making 100% of your inventory available across all your sales channels.
Out-of-stock products are automatically removed from your online offers, avoiding the inconvenience and costs associated with out-of-stock sales.
Every stock movement is recorded in real time in an intuitive back office, guaranteeing reliable, transparent management.
Your inventory is synchronized in real time across all your sales channels and warehouses, enabling smooth order fulfillment.
Use of WMS management tools
The core of our solution is our Warehouse Management System(WMS PME), which provides real-time visibility of your inventory. It intelligently plans picking tasks and optimizes picking routes. Your pickers have access to all necessary information via mobile terminals such as scanners or PDAs. This level of automation minimizes errors and cuts order-picking times considerably.
Logistics picking
At Shippingbo, we understand that logistics picking is a delicate stage that directly influences customer satisfaction and operational efficiency. That’s why we’ve designed a comprehensive solution that tackles this issue in an innovative way. A variety of picking modes are available at Shippingbo:
- Pick to Light: this option uses indicator lights to guide operators in picking items.
- Rucher Mobile: these mobile picking carts are equipped with a laptop computer and a barcode scanner, enabling real-time order picking.
- Fixed beehive: stable, permanent workstation dedicated to picking, equipped with order management and traceability tools, guaranteeing efficiency and precision in product selection.
- Pick and Pack: the picking stock is placed in the immediate vicinity of the packing station, enabling smooth, continuous organization of order packing.
- Picking sessions: a set of unified orders based on common shipping criteria, facilitating the picking process.
Use of adapted equipment
We know that the right tool can make all the difference. That’s why our solution is compatible with a variety of handling equipment such as forklifts and pallet trucks. The right equipment not only facilitates the picking process, but also enables access to more complicated storage areas. What’s more, the use of scanners and PDAs integrated into our WMS system reduces processing times and increases the accuracy of operations.
Ready to move up a gear? Automation is waiting for you!
Don’t wait any longer to propel your company into the future! Automation isn’t just a trend; it’s a revolution that’s transforming the world of logistics. By optimizing your warehouse, you’ll not only gain in efficiency and cost, you’ll also give yourself the freedom to focus on what really matters: growing your business and delighting your customers.
If the prospect of fewer errors, lower costs and happier customers appeals to you, then it’s time to take action. The road to an automated warehouse is far less complicated than you might think, and the benefits are very real.
So, are you ready to make the leap to efficiency and growth?
Contact us to find out how we can help you make this transition a breeze. Take the first step today to build the company of tomorrow!
