Tag Archive for: Vertical Lift Machine

7-automation-solutions-to-support-ecommerce

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 ActionHAI 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: Goods-to-Person Tote Handling AS/RS with Opex Perfect Pick

Goods-to-Man Tote Handling AS/RSHigh-speed AS/RS tote handling solutions offer scalable goods-to-person picking that improves the speed with which orders are picked, increases order accuracy, and reduces labor costs related to the picking process. It is a low-risk solution for those looking to introduce automated solutions into their operations. An additional benefit of this solution is that an operator can customize either the software or the system quickly if needed.

These systems offer high-density storage both vertically and horizontally within the system with robots that deliver products to a packing station or workstation for further fulfillment. It utilizes put-to-light technology that offers a high degree of accuracy, even with high volumes of order picking.

Solution 3: Autonomous Mobile Robots (AMRs)

Autonomous Mobile Robots (AMRs)AMRs offer a wide variety of benefits, including facilitating complex fulfillment, zone picking, each picking, case picking, maximizes labor, reduces labor costs, and can be designed to be scalable, flexible, and adaptable to nearly any fulfillment process. Because they do not require massive investment or even a WMS, on-demand automation solutions like AMRs are becoming adopted widely, especially for those looking to make low-risk introductions into automation.

Solution 4: Put to Light Tables/Workstations

Put-to-Light TablesPut-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 5: Mixed Use of AMRs, Pick Modules, and Conveyors

AMRs and Conveyor CombosWe’ve touched on the integration of AMRs 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.  Click here to learn more about this solution.

Solution 6: Introduce Automation without Massive Infrastructure with inVia Robotics

inVia Robotics ActioninVia Robotics offers a “crawl-walk-run” approach to introducing automation with their PickMate, Picker Robots, and PickerWall solutions. Users can integrate robotics at your scale, ultimately improving productivity up to 10x while seeing a return on investment on day one of implementation.

inVia is the only technology that can create a goods-to-person picking environment out of an existing pick module while not requiring massive infrastructure changes within your facility.

Their unique robotics-as-a-service (RaaS) and software-as-a-service (SaaS) subscription models offer an ideal place to start automation because the subscription model removes the massive capital expenditure from the equation

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!

Dynamic Solutions Beat Labor Challenges

Throughout the supply chain, businesses are experiencing labor challenges in various ways, and it has taken a toll on throughput and profitability for many.

First of all, labor availability is at an all-time low, and fulfillment centers are routinely operating at below capacity because of it. That puts undue pressure on the remaining workers, who are then overextended in attempting to meet consumers’ increasing expectations on quicker delivery for an ever-increasing share of e-commerce orders. In this environment, fulfillment centers are also adjusting to fewer shipments of full pallets and a more significant share of each or order picks, which are more expensive and lead to increased labor costs.

Plus, because labor availability is so low, companies are required to raise wages – and sometimes add bonuses – to attract new employees. That factor makes employee retention more difficult because now there is more competition for those higher-paying jobs, so workers are more apt to jump from one company to another. So, in changing careers and changing companies, quality control is affected as more employees need to be trained.

In short, the labor market is a mess right now. COVID-19 and other external factors have caused a dramatic shift in supply chain employment, and companies are feeling the pain of all these changes. Some have adopted dynamic strategies to reduce dependency on human labor for fulfilling orders, and some are in the process of investigating potential options for their operations.

In fact, one of the most common themes we hear from clients is that they may have waited too late, and now they need to play catch-up. We have found that clients are getting their biggest “bang for the buck” on integrating solutions around their picking, packing, and replenishment operations.

Below are a few dynamic solutions we design and provide that may help your business catch up to meet today’s challenges, but in reality, these solutions should also come with a roadmap to help your operations adapt to future challenges that may be unforeseen.

Adding Conveyor and Sortation Solutions

Conveyor and sortation solutions can be a solvent for labor challenges, primarily by reducing the amount of physical travel required by transporting products long distances within a facility. Through proper design, conveyors can dramatically improve fulfillment speeds, add quality control, and improve safety in a facility.

Even if you have a conveyor system currently running in your facility, it may be time to re-evaluate your design as demand and needs change. Retrofitting existing conveyors with new parts, sortation solutions, or new motors can also make a sizeable impact on your replenishment, picking, and packing efforts.

Condense Your Footprint with Vertical Lift Modules

While condensing your storage doesn’t always directly solve labor challenges, vertical lift modules (VLMs) offer various benefits to fulfillment operations, particularly when it comes to picking items to a cart. VLMs offer a fully-automated goods-to-person picking and storage solution that can be ideal when your process involves small-to-medium products.

Pick-to-light batching tables can be incorporated to allow for picking multiple orders to drive higher pick rates and eliminate guesswork from the batching process. With these high pick rates and additional throughput and accuracy, you can drive labor savings.

Introduce Automated Warehouse Robotics

Autonomous mobile robots (AMRs) and autonomous guided vehicles (AGVs) are two typical warehouse solutions to labor challenges because of their fulfillment rates, operational costs, safety benefits, and order accuracy. Our partners at Fetch Robotics and inVia Robotics work with your labor force to support replenishment, picking, and transportation of products. These solutions can be installed as a subscription service, meaning you don’t have to invest in massive infrastructure at your facility.

These solutions integrate with your warehouse management systems (WMS) to optimize pick paths to support your pick process or do the picking entirely, depending on your needs. Ultimately, though, they remove the costliest aspect of fulfillment – humans walking through a warehouse.

Reduce Costs When You Automate Your Packaging

Especially as a greater share of orders are being shipped individually than by-the-pallet, automating your packaging process can support increased throughput and lower labor costs. From case sealers to auto-baggers to print-and-apply labeling systems, there are several solutions that can prevent you from paying someone to package individual or group orders.

These end-of-the-line solutions can automatically measure and add void-fill, reducing waste, freight costs, and can improve customer satisfaction along the way.

Invest in Automation with Goods-to-Person Picking Systems

Even if you have no level of automation in your operations, it may be worth investigating how to integrate automated goods-to-person picking systems in your facility. However, before diving in too deep, we recommend speaking with an expert that has conducted a data-driven analysis of your material flow to determine the right solution for your business goals.

Automated storage and retrieval systems (AS/RS) can come in cart-based solutions, crane-based solutions, cart-crane combinations, mini-load AS/RS, and more. They all drive extremely high pick rates, optimal storage design, ergonomic support and can scale as your business goals grow. However, because there are so many options out there, finding the right solution requires the design and expertise of a proper project partner. We’d be happy to discuss these options with you!

Need Some Advice? Contact an Expert

Our team of experts has experience with various solutions that can relieve the dependency on labor and drive an ROI by increasing your throughput. For us, solving labor challenges is less about eliminating workers but more about keeping your best employees around by making their jobs more accessible, more consistent and creating opportunities for less wear-and-tear per pick.

Automation Solutions for Dense Storage

Whether it is time to reconfigure your operations within a warehouse or design a new warehouse, a common goal in the design team is to get the most capacity out of each square foot of the facility. Wasted space – both horizontally and vertically – means lost potential revenue because, by default, you are not able to store as much as you would with dense storage solutions.

Traditionally, facility design engineers would take standard pallet racking – a lot of it – and find ways to slot inventory appropriately to optimize storage. They would look at opportunities to reduce unused space while factoring in order frequency and a few other variables. Occasionally, dense storage options like pushback racking and carton flow get included as well. Others would fill their facility with a sprawl of shelving or a combination of all the above.

But what happens when the supply chain changes? What happens when consumer expectations change? What happens when you need to incorporate more safety stock or turn around orders faster?

When considering the design (or redesign) of a facility, there are great alternatives to increase storage capacity within your footprint by introducing a combination of dense storage and automation solutions at varying degrees.

By introducing automation, warehouses can maximize space utilization with good throughput in the face of labor challenges. Especially as e-commerce continues to rise while traditional full-pallet shipping falls, warehouses are looking to adapt by doing more work with less labor.

So what options are out there for those making these decisions? Let’s take a look.

Semi-Automated Deep Lane Storage Solutions

For those who store products on pallets with large quantities of pallets on hand for specific SKUs, semi-automated deep lane storage solutions – commonly referred to as pallet runners, shuttles, or moles – can add capacity to warehouses by using technology to load, store, and unload pallets. A cart (or runner/shuttle/mole) transports a pallet along a lane with these storage systems and empties it into the first available storage position. These systems are dense in that they can store 12-40 pallets per lane, depending on the configuration. They are adaptable, capable of running continuously and help reduce damage to products and racking structures by staying within their respective lanes.

Example: AutoMHA’s Pallet Runner

Automated Storage & Retrieval Systems (AS/RS) for Unit Load Handling

Cart-Based Solutions

In some ways, like the semi-automated deep lane storage, there are cart-based unit load AS/RS pallet handling solutions that can move bi-directionally to store and retrieve pallets and products automatically. These shuttles are highly reliable, easy to install, and adapted and scaled when growth calls for additional throughput needs. Cart-based systems can often provide higher throughput & better storage density than traditional crane-based AS/RS systems.

Examples: Optimus Automation’s Robotic Pallet Shuttles, Advanced Storage’s Rover

Crane-Based Solutions

Crane-based AS/RS technology has been around for some time in warehouses. These cranes can store and retrieve pallets within a storage system that maximizes vertical storage density at high speed. These systems offer improved efficiency, simple operation, and an easy maintenance plan.

Example: Daifuku’s Stacker Cranes

Cart-Crane Combination Solutions

Crane-based AS/RS systems that also incorporate carts provide the cost benefits of crane solutions with the added storage density that can be achieved using carts. These systems can accommodate both deeper lane storage and single or double-deep storage if there is a mix of typical on-hand quantities per SKU.

Example: AutoMHA’s AutosatMover

Dense Storage Solutions for Less-Than-Pallet, Unit Handling Environments

Mini-Load AS/RS Shuttles

Mini-load AS/RS shuttles are excellent in environments in which high throughput rates are required for picking eaches or cases within a distribution center. They significantly increase the storage density, accuracy, and speed with which products are stored and picked, and adapted to different building configurations. As a solution for getting products as quickly as possible from storage to staging, these systems can also serve as a short-term buffer system or act as manufacturing support for production operations.

Example: Dematic’s MiniShuttle

Vertical Lift Machines (VLMs)

VLMs offer warehouses a goods-to-man picking solution, ideal for storage and picking of small-cube and slower-moving items. They are great because they maximize floor space – 5,000 square feet of traditional storage can fit into about 150 square feet because of the machine’s height. VLMs offer high pick rates and can store a large cubic volume of a product. They are typically paired with a pick-to-light batching table and utilize software to allow for picking multiple orders simultaneously.

Example: Kardex’s Vertical Lift Modules

Vertical and Horizontal Carousels

As a high-density storage solution with a small footprint, vertical carousels are ideal for storing small parts. Products are organized by SKU in individualized boxes or totes that are secured to a series of shelves that rotate like a Ferris wheel. They revolve around a track and are accessible to a picker through a pick window. Horizontal carousels rotate similar to a dry cleaning rack, which allows your worker to stay in one area while the products turn to them. This action reduces travel distance and picking time, with multi-window and multi-level configurations available.

Example: Kardex-Remstar’s Vertical Carousels and Horizontal Carousels

Other Robotics-Based Dense Storage Automation Solutions

Ultra-High Density Goods-to-Person Storage and Buffering System

If you are in the market to bring maximum flexibility, scalability, and storage to your operations, ultra-high-density storage and buffering system will get you there. This system brings optimal storage for warehouses with many thousands of SKUs that need to facilitate very small order sizes, particularly in a small footprint warehouse. Ideal for e-commerce, these systems can facilitate multiple simultaneous orders with 3-dimensional automated picking that brings with it highly accurate order picking within an ultra-dense storage grid.

Example: Dematic’s AutoStore

3-Dimensional Automated Order Picking Systems

Automated dense storage solutions can also come in the form of a 3-axis storage system that uses autonomous mobile robots to facilitate storing and picking products. With these goods-to-person systems, an operator will give the AMR an order, which will then travel along a floor path to a specific location. From there, a shelf-climbing robot will lift the AMR to a particular location where it will select the product and deliver it back to the operator for batching. This system saves on labor and increases order speed and accuracy. They can be completely customized to meet your needs and, with quick installation, adaptable to expand as your operations grow.

Example: Exotech’s SkyPod

Which Automation Solution is Right for Your Operation?

These are just a few of the options out there, but there are a lot more that may be the right option for your operation. Sorting through and finding the right choice to meet your needs can be challenging.

We have a team of experts on hand to learn about what set of challenges you are seeing in your warehouse today and learn about what you see down the road. You may only need to invest in entry-level automation, or you may need to evaluate a fully automated facility. In reality, the answer is likely in between. Call us today and speak with a Storage Solutions expert!

Storage Solutions Each PIcking E-Commerce

“Each picking” is a common style of order picking in the rising world of order fulfillment through e-commerce channels. With each picking, individual products or SKUs are selected from a storage medium instead of choosing an entire case or pallet. Once the order is complete, the picker transports the order to a packing area to be shipped.

Especially at a high volume, this process can be relatively highly labor-intensive, add to rising labor costs, and potentially cause delays in order fulfillment. Plus, because order sizes are getting smaller – in line with a rising share of e-commerce orders – warehouses and distribution centers need to be aware of various storage solutions that support each picking. This knowledge is particularly valuable as we continue to adapt to a rapidly changing supply chain.

light-duty-cantilever

Cantilever Shelving

So, which storage solutions allow for your warehouse to be best equipped to facilitate each picking?

  • Cantilever – Cantilever arms can be attached to pallet rack uprights and be outfitted with wire decks to keep products like clothing and other soft goods within a multi-level system from a picking perspective. This configuration can make continuous picking and replenishment easier for workers. Cantilever shelving can also be utilized as a creative way to put small-cube and slow-moving objects on a shorter pick path.
  • Carton Flow – Primarily used in first-in, first-out picking situations, carton flow uses gravity to feed products forward from a rear-load design. When an item is picked, the next case or object with the same SKU moves forward with gravity’s help to the pick face. This style of racking is designed for high-volume each picking where you need to keep operator travel low.
  • Spantrak Carton Flow

    Carton Flow

    Hand-Stack Racking – Similar to cantilever shelving, hand-stack racks are traditionally used for storing products that may be too bulky or large for standard bin shelving. This racking style generally uses wire decking or a solid surface to act as shelves within selective pallet rack with variable heights per row to best fit products in cases or cartons.

  • Modular Picking Carts – Modular picking carts are great accessories for pickers as they fulfill an order. They can accommodate and organize the storage of one (or a few) products of several SKUs, a regular feature of e-commerce orders. These mobile carts can also be configured to be either single-sided or facilitate back-to-back storage, depending on your products’ sizes.
  • Vertical Lift Machines (VLMs)
    vertical-lift-machines

    Vertical Lift Machines

    – The primary benefit of a VLM is the maximization of vertical space in your warehouse. For instance, a VLM may be capable of storing the same amount of small cube items that take up 5,000 square feet of floor space in a warehouse and transfer that into about 150 square feet of floor space, giving you a 90% decrease in your footprint. This goods-to-man solution allows operators to pick orders accurately and efficiently at a high rate by delivering products in trays controlled by your already-existing Warehouse Management System (WMS).

Which Solution is Best for Your Facility?

For the most part, determining which storage solution is right for you depends on the size of the products stored in your warehouse and how quickly your orders need to be fulfilled. However, that time keeps shrinking due to changing customer expectations.

Having an expert by your side can help determine the best answer, especially if you are looking at adjusting pick processes, facility layout, and storage optimization.

Of course, our team is here to help! We would love to get a conversation started around the challenges you see in meeting customer expectations, rising labor costs, and storage needs. With our “simple, smart, strategic” approach, we can develop the optimal solution to meet your needs. Give us a call today!

Increase Storage Capacity with Dense Storage Solutions

There can be many reasons why a distribution center or warehouse would increase storage density within their facility. Perhaps the company has grown but does not feel that investing in a new facility is the right move. Maybe they are changing their inventory strategy to combat future disruptions in the supply chain, so they want to add additional safety stock of popular products. They could even be adding a new set of products or SKUs and need to accommodate that capacity growth.

When a company is evaluating how to increase storage capacity, there comes the point in which the business needs to determine the best path to create additional storage without increasing the size of its footprint.

What do you do when you have more of each SKU on hand than you used to?

Dense Storage Solutions for Large Items

Pallet Rack Pushback Dense Solutions

Pushback Racking

  • Pushback Racking – Pushback racking uses a cart system that is pitched from back to front so that stored materials can gravity flow down into a pick position. When a new load is added, it pushes back pallets already on the rack. This system is ideal for Last-In, First-Out (LIFO) inventory management.
  • Pallet Flow Ideal for First-In, First Out (FIFO) inventory management, pallet flow is created when multiple pallets are added from the storage system load end, and rollers propel pallets downward toward a pick position at the opposite end of the system, allowing for efficient picking and unloading.
  • Pallet-Flows

    Pallet Flow

    Drive-In / Drive-Thru Drive-In and Drive-Thru racking allow forklift operators to either drive in or drive through racking to pick up or drop off pallets. Because the system requires fewer pick aisles, this style of racking can accommodate a more considerable amount of pallet space than standard racking systems.

  • Semi-Automated Deep Lane Storage With this storage system, a motorized cart (operated by a remote) is used to pick up pallets and transfer it along the storage lane. This type of racking is very user-friendly and allows for quick retrieval of pallets.

Dense Storage Solutions for Small Items

  • vertical-lift-machines

    Vertical Lift Machines

    Vertical Lift Machines (VLMs) VLMs are goods-to-man picking solutions that help deliver trays of smaller products to a pick area. These machines are typically suited for small cube and slower-moving items.

  • Mini-Load AS/RS – Mini-load automated storage and retrieval systems (AS/RS) are a storage system that will automatically store and retrieve products under 350 pounds within an engineered rack system. These systems allow warehouses to have a smaller storage footprint by creating a vertical, automated storage system.

Several options are available, and the right storage medium will depend on the items you are warehousing. Once you determine the correct solution for your operations, you will also need to reconfigure your picking operation to maximize pick efficiency. Of course, we are here to help you throughout the decision-making process and be a partner that guides you to the correct decision.

No matter what challenges you are seeing, we have the expertise to match you with the appropriate solution suited to meet those challenges while accounting for future growth. Give us a call today!

Temperature Controlled Storage

Temperature-controlled storage is a subject that is getting significant attention lately, and for a good reason. It is integral to the storage and supply of climate-sensitive items such as food, pharmaceuticals, and similar items. If these items rest for too long in the wrong climate – without temperature-controlled storage – they could be damaged or ruined. Of course, that loss of inventory the last thing anyone wants for their business.

The growing popularity of e-commerce, also known as the “Amazon Effect,” brings with it the need for more temperature-controlled storage space in warehouses and distribution centers across the globe. Citing a 2019 report published by Los Angeles industrial retail giant CBRE, experts anticipating an expected expansion of more than 30 million square feet of cold storage by 2024. The demand for these types of facilities is “niche, but one that is really going to take off,” according to the CRBE.

Temperature controlled space can be costly to construct and operate. Common challenges also include creating a design that is optimal for employee working conditions, safety, and maximizing storage capacity within the cubic space available.

When going this route for your company, you will want a partner that can give you the exact solution that meets your needs. By working with our expert design team, you can rest easy knowing you will get optimal utilization out of your facility. Our priority is to make sure that not only are your needs met but that your project is also completed on time and on budget.

Available Solutions for Temperature Controlled Storage

  • Drive-in Rack
  • Pushback Rack
  • Semi-automated deep lane storage system
  • Fully automated, cart-based AS/RS system
  • Dense storage methods with “pick tunnel” designs incorporated to accommodate case picking
  • Carton flow rack for case pick items
  • Vertical Lift Machines (VLMs) for each pick items
Vertical Lift Modules

Vertical Lift Machines (VLMs) are the automation solution that could bring your operation to the next level. Automation is, of course, becoming necessary in modern facilities, making VLMs the perfect solution to add to your operation.

VLMs are a “goods to man” picking solution that allows users to pick orders efficiently while optimizing space utilization within a facility. Its internal software allows this seemingly complex machine to be one of the most user-friendly tools in your warehouse.

As an extremely customizable machine, VLMs can be catered to your every need. Their location sizes can be easily adjusted “on the fly”, and their functionality takes all the guesswork out of it, maximizing pick accuracy. In addition, the extremely high pick rates and space utilization will lead to labor savings and increased revenue. With its ability to move up to 120 trays per hour, multiple machines can be grouped for maximum efficiency.

Finally, VLMs can be an integral part in decreasing your footprint in your facility. For example, in a recent project, adding VLMs to the facility decreased our customer’s footprint from 5,000 square feet to 150. That’s over a 90% increase in space for other necessary equipment.

Want to learn more about Vertical Lift Machines? Click here for more information!

Riverside, MO, Automated WCS

Our latest project took us to Riverside, Missouri, where we were tasked with setting up a complete, automated warehouse solution for our client. Our warehousing veterans used their expertise in order to fulfill the customer’s needs.

This facility would be acting as a distribution hub, meaning that they would be sending out items of different size, weight, case type and more. The solution would also need a 100% visual quality assurance checkpoint, along with powered conveyors. Our customer needed a facility that would maximize productivity and handle increased business volume, without needing to increase labor.

Complete Automated Warehouse CAD Drawing

AutoCAD Drawing of the new facility

Above all, our solution was to create a facility with specialized sections, all for a certain task. The six sections included VLMs (Vertical Lift Machines), powered conveyor with a sorting function, broken and full case picking areas, a quality assurance area, and more!

At Storage Solutions, our team comes from decades of experience. Our experience, combined with our network of trusted partners, allowed us to get our client’s facility running at optimal efficiency while also sticking to their timeline and budget.

Take a scroll through the full case study here!