In our last article, we explored how automated solutions such as ASR and PopPick can be introduced into warehouse facilities to optimize space, bolster productivity, improve picking accuracy, increase inventory control and improve worker ergonomics. In today’s article, we will drill down on specific storage scenarios and examine the best robotic technologies that businesses should select for each scenario.
Table of Contents:
Pallet Storage
Pallet storage is an extremely common storage scenario in warehouses. It is a popular storage choice as it allows for the maximum utilization of space by increasing the vertical space that a business can use in the warehouse.
Traditionally, forklifts or ASRS are used to lift and transport pallets. However, forklift safety has come into the spotlight in recent years, with a rising number of reported accidents related to forklift use in warehouses. In the United States alone, there are 61,800 forklift accidents per year, with 34,900 of these accidents resulting in serious injury. Poor maintenance of forklifts, ground obstructions and blind spots are just a few conditions that can pose safety risks. Besides the safety of your staff, goods safety can also be compromised. In a busy warehouse, forklifts can drop pallets, run into them or pierce part of the board with the fork.
Embrace Industry 4.0 – Siemens Switchgear
In light of these risks, other technologies have been innovated to offer a safer alternative. One such technology is automated picking solutions. Geek+'s Goods-to-Person solutions use P-series AMR picking robots to move pallets to the picking station, improving accuracy and safety of operations. One such successful deployment of AMRs is in Siemens Switchgear's Shanghai factory. By implementing a fully automated and flexible system, combining four AI-driven robotics solutions, the world-leading manufacturer has leveraged Industry 4.0 innovation to improve its service to its customers by leaps and bounds.
4-Way Shuttle Evolution
A second such technology is the 4-way shuttle system. In 2021, Geek+ launched Smart Mixed Case palletizing, a solution that combines Geek+ AMRs and WSR Solutions’ intelligent palletizing algorithm to help warehouse operators systematically handle the processing of multiple outbound orders in an efficient, safe, and flexible way. Pallets are efficiently stored in high-density racking and flexibly moved by four-way shuttles and raised vertically by lifts.
Carton Storage
Carton storage is another commonly seen scenario in warehouses. Companies that handle small products and boxes tend to implement carton storage for picking. Traditionally, warehouse pickers use ladders to manually reach and open the cartons, or bend to reach cartons on the lower tiers – greatly increasing the risk of injuries.
In 2018, according to the USA’s National Safety Council, the cost of medical bills, damage to equipment, loss of production time, and training for replacement staff amounted to a staggering $84.04 million per week in the warehousing industry. Beyond being responsible for the physical wellbeing of their employees, the financial cost of warehouse safety risks should give businesses the impetus to take action.
Totes-to-person Office Supplies - Comix
To facilitate safe carton storage and handling, businesses can consider Geek+’s RoboShuttle solutions. In 2021, in order to address office supplies company Comix’s warehouse challenges, Geek+ deployed a high-density robotic solution, RS+P40, combining a four-way shuttle system in Comix’s 10,000m2. warehouse.
With the help of an AI algorithm, the intelligent tally system automatically adjusts the inventory distribution, which greatly improves the outbound efficiency of Comix's warehouse orders. In addition, the P40 robot can be automatically raised to a comfortable picking height for the operator, which improves the picking efficiency while reducing the risk of injury for workers.
CE Certification
Geek+ ensures the quality and safety of its products through regular inspections by trusted global certification bodies. In 2020, Geek+’s picking safety system was the world’s first picking safety system to achieve CE Certification by global certification body TÜV Rheinland. It tests various aspects, from space usage and robot control to the dispatch system and a fire-control linkage system.
TÜV Rheinland also declared RoboShuttle C200M’s man-machine interaction to be safe and efficient with employees positioned at workstations and the robot navigating the storage area, bringing bins of selected goods to the employee. To further ensure reliable man-machine interaction, the robot has an electronic control system including sensors. Regarding the software, the robot can realize multiple functions such as emergency stop, local deceleration, and fire linkage under the control of the safety dispatch system, minimizing potential safety hazards.
Loose SKUs Storage
Another type of storage choice in the industry is loose SKUs storage. However, piece picking traditionally brings about its own set of vulnerabilities:
- Double handling stock could be costing you 9% of payroll
Whether at a pallet, case, or order level, double handling stock will slow your process down and add a bottleneck to the operation. McKinsey reported that this sort of process improvement could be worth a 4-9% saving opportunity. In addition, it is likely that every time you handle a product, you introduce a potential for error and the next type of process waste.
- Half of the pick payroll is in travel
Especially when unladen and not moving stock, travel will cost you time and money. There are many root causes for excess travel – and they all add up. Often, they result from excessive and independent processes which must be combined and simplified. Walking could represent 50% of your pickers’ time – so there is a large labor cost involved and opportunity.
- Time is excessively spent on checks
Checks are great when they find errors. But every single check that finds items as expected is, in fact, a waste. McKinsey reported that 33% of the time is spent on additional checks. The skill, therefore, comes in knowing where the errors are.
- Another efficiency killer in hiding: waiting
This is another critical way to waste time and create bottlenecks in operations. Whether you are waiting for systems to process, due to congestion and traffic in the warehouse, delays due to downtimes and maintenance, or waiting for equipment availability, these slowdowns prevent your warehouse from operating effectively and serving your customers to the best of your ability.
Warehouse Productivity Optimizer - PopPick
One solution for loose SKUs storage is Geek+’s latest innovation, PopPick. PopPick is a leading-edge robotic automation solution, best described as the future of Goods-to-Person, solving issues of efficiency and space by revolutionizing the picking station.
The solution has multi-size compatibility to effectively handle items of various sizes with different types of storage units, such as totes and cartons. Up to 12 columns of totes are stored densely in an inventory area using pallets or mobile racks 3.7 meters high for 50% more storage density compared with the original Goods-to-Person system.
One rack is optimized to store and transport up to 60 totes, allowing 4x more transportation efficiency. By optimizing the number of robots and maximizing throughput capacity and space utilization (storage density can be improved by 4x), PopPick can reduce costs by 50%. Other than gains in business productivity, PopPick also prioritizes worker ergonomics to ensure workplace safety and safeguard employee wellbeing.
P-series robots
Another solution to handle loose SKU storage is Geek+’s P-series robots. In the case of global sporting goods retailer Decathlon, Geek+ implemented an RFID technology-based goods-to-person picking and inventory program for Decathlon’s Kunshan warehouse.
Geek+’s P-series picking robots helped Decathlon achieve massive improvements in the form of a 50% increase in space utilization, a 300% increase in picking efficiency, and an increase in shipment capacity to 40,000 pieces/day.
As we have examined, different warehouse storage scenarios require tailored automation solutions. Whichever way your warehouse operates, Geek+ is keen to work with you to achieve the best results possible with our award-winning robotic solutions. Contact our consultants today and let’s kickstart your automation journey together!
Found this article helpful? Stay tuned for the third and final part of the series, ‘Automation 301: Preparation of AMRs’ which will talk about the preparation of hardware and software before automation.
