How technology is transforming the world of warehousing

Automation is vital to warehousing and distribution centre operations to meet the growth in volume and speed in the on-demand economy and the need for greater inventory accuracy while filling labour-gaps and supporting the existing workforce.

It’s no surprise that in the last two years, nine in 10 warehouse operators have reported average shipping volume increases of 23 per cent in business-to-business fulfilment, and similar average increases for direct-to-consumer fulfilment.

Shifts in e-commerce means warehouses and distribution centres are expected to deliver orders faster than ever. In the Warehousing Vision Study Zebra conducted, 82 per cent of retail decision-makers agree they’ve increased their focus on supply-chain operations. All supply chain stakeholders are finding fulfillment and shipping complex.

Every company and supply chain leader needs to know how long it should take – and does take – to move goods from the first mile to the last mile. No one should be left wondering as to where the goods are, and yet this continues to happen.

Today, supply chain leaders need to move beyond capturing data from sensors to joining the dots between devices, front-line workers, assets, inventory, and workflows. This information needs to be incorporated in a useable way into operational decision-making and actions on the warehouse floor and logistics planning.

It’s about incremental changes, reducing seconds and minutes from tasks resulting in time savings of hours and days and optimising specific workflows.

The digitalisation of data is not the finish line; it is just the first step to creating a more resilient, future-ready operation.

Digitalisation of workflows is next. Once established, it becomes easier to automate as part of a multi-year, incremental improvement strategy. Automating parts of the business does not need to take years – autonomous mobile robots (AMRs) can be rolled out in hours, and multiple workflows can be automated in days.

Why autonomous mobile robots?

I believe that AMRs are one of the fastest ways to drive business process improvements and support workers without complex, resource-intensive modernisation projects. Automated workflows can be constantly refined and scaled over time using the same solution. So, when a company needs additional capacity, it can put more AMRs in the field to support or help onboard new workers.

The instant AMRs start to move materials, bins, carts or pallets; they are returning money straight back into the operation. AMRs are versatile, but they need to be configured to support a specific application and can integrate seamlessly with human-involved workflows to deliver the benefits.

Workflows become consistent while processes become steady, and people become more available to keep manufacturing, processing or distribution operations running smoothly, even in surge periods.

Reliable, dynamic AMRs do jobs that can be physically and mentally exhausting for people. With a cloud-based robotics automation platform, people and robots can collaborate and maintain full control over the operation and keep orders moving into the market. AMRs support skilled workers, give them back time to receive, process, produce, pick, pack and ship more orders.

Walking is not a good use of time in manufacturing, distribution, third-party logistics or warehousing operations. So, at the very least, companies should be using a flexible automation solution such as AMRs for every task that would traditionally require people to walk, push, pull or carry items from one aisle, station or line to the next.

The same study highlights the benefits that associates have seen from working with AMRs; including reduced walking/travel time (83 per cent) and reduced errors (73 per cent).

Depending on the use case, we’ve seen robotics automation solutions help warehouse operators increase productivity by 2.5x, double throughput and reclaim 15 per cent of their space. Almost one quarter (23 per cent) of European warehouse operators have already deployed some form of AMR, which is in line with the global trend (27 per cent). Within five years, these numbers are expected to grow to 88 per cent in Europe and 90 per cent globally.

Bridging the gap

Robotics technology is not at a point where machines can replace people completely. Labour intensive operations, like assembly and warehousing, demonstrate the best model is combining machines with human talent to improve productivity, efficiency and quality. Machines such as AMRs allow people to focus on what they do best: use their dexterity, solve problems and identify opportunities for innovation.

As automation moves into the mainstream, customers are not asking, “How can I automate this task?” but, “How do I automate this process?” The focus then is on software solutions that orchestrate and coordinate a range of digital devices and activities to work together to smooth and speed the process.

Without the help of robots, people aren’t going to be able to keep up with global commerce demands. With robotics automation, supply chain companies will do more than keep up – they’ll strengthen agility and performance.

Hozefa Saylawala is the director MENA at Zebra Technologies

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