There is a rapidly growing market for interest in automation solutions, especially in response to the COVID-19 crisis that has reshaped supply chains globally.
Before the crisis began, businesses of all types were slowly shifting to support e-commerce. However, when the pandemic hit, that shift suddenly forced those interested in these solutions to re-evaluate if automation was required to meet customer demand. With the recent acceleration of e-commerce demand, many fulfillment centers need to incorporate automation to a higher degree.
To meet customer demand – where the time between order and delivery expectation is shorter than any time in history – warehouses need to change. Warehouses that are not fully prepared for this rapid rise of e-commerce often rely on an excessive amount of labor (including additional overtime), missing ship dates, and do not meet customer expectations on order accuracy or fulfillment times, all while confronting an ever-increasing volume of SKUs.
The pain points are all building up for those who have not yet adjusted. In those cases, how does one respond?
Some businesses start from scratch by building new facilities, while others are looking to adjust by retrofitting under their current footprint. These companies are looking to increase storage density, reduce time and costs, and achieve higher throughput capabilities by introducing automation into their processes.
Several solutions help warehouses and distribution centers stay competitive and thrive in today’s changing world. Below, we have highlighted seven automation solutions we have seen be useful in these efforts, no matter what level of automation your facility currently has implemented:
Solution 1: Goods-to-Person Picking with HAI Robotics
HAI Robotics is an intelligent, efficient, and flexible automation solution that utilizes a combination of HAIPICK robots, customizable storage units, software, and workstations to create a robotic goods-to-person picking workflow in a warehouse setting. These robots can handle up to eight cases simultaneously and reach heights up to 33 feet, increasing operational efficiency by up to 4x while also increasing storage density by up to 130%.
This solution replaces the repetitive, time-consuming costs of manual storage and handling and introduces a goods-to-person technology that can drastically improve fulfillment efforts.
Solution 2: Vertical Lift Modules (VLMs) for Efficient Goods-to-Person Picking
Vertical Lift Modules (VLMs) are an ideal automation solution for e-commerce businesses looking to streamline order fulfillment and maximize vertical space. These goods-to-person systems automatically deliver trays of stored items to an ergonomic access point, reducing travel time and increasing picking efficiency.
VLMs offer high-density storage in a compact footprint, making them perfect for facilities with limited floor space but growing SKU counts. With configurable tray heights and intelligent software, VLMs ensure optimal storage organization and quick access to inventory. For e-commerce operations managing a wide range of products and fluctuating order volumes, VLMs provide both the flexibility and scalability to keep up with demand.
By bringing items directly to the operator, VLMs reduce picking errors, improve throughput, and minimize physical strain on warehouse staff—resulting in faster, more accurate order fulfillment.
Solution 3: Put to Light Tables/Workstations
Put-to-Light systems are an automated sortation method to break down larger product quantities into smaller individual orders. Known as the “scan and sort method,” this order fulfillment method takes items that are usually batch picked beforehand and transports them to the put station. The operator will scan a bar code on individual items, and the lights will illuminate with any customer order including that product. This technology solution will increase productivity as it reduces the time associated with searching for the put location. By the time the operator is done, the next product is already waiting, meaning it is a nonstop picking environment where workers are never waiting on automation.
Put-to-Light offers the same hardware devices and software as pick-to-light, meaning you can utilize both systems on one platform. This process will be beneficial when it comes to training new employees to use this technology solution. This system’s primary goal is to give you the ability to pack and ship more orders in less time while reducing errors.
Solution 4: Mixed Use of Pick Modules and Conveyors
We’ve touched on the integration of robots in conjunction with pick modules in addition to (or in place of) conveyors here. In short, by using this solution, you are shifting the work of your labor force to more valuable tasks. Like many automated solutions, it lessens the pick process’s length and gives you a flexible, scalable solution to adjust as e-commerce continues to grow.
Which is Right for You?
Which is the right solution for you? Will you need a WES/WMS system? Do you need a partner to help you consider using an engineered solution in the future?
There are several factors distribution centers need to consider, not only to meet today’s demand but also to facilitate growth and adaptability for future unforeseen changes in fulfillment expectations.
We have the design and expertise to partner with you through the decision-making and implementation processes. Give us a call today!