Advances in technology have increased the efficiency of warehouse processes in many ways. These technologies can now augment the work of humans as well as automate tedious, manual tasks allowing the labor team to focus on more complex tasks. Warehouse automation takes on many forms, such as machines and robots, that assist workers with distribution-related processes that start when goods arrive at the warehouse all the way through when they leave the building. Implementing warehouse automation solutions can help increase the productivity and accuracy of those processes while reducing labor costs and improving overall safety.
This does not equate to robots replacing the need for human workers. These automation solutions take on the tedious tasks that required long hours of work and allow employees to focus on other less labor-intensive aspects of the distribution process, providing a safer environment for all involved. Warehouse automation can cover everything from unloading trailers to fulfilling orders, but humans are still a vital part of the process.
One technology that is a part of automation is Sortation. Manual sortation requires the labor force to organize, categorize and separate products and materials. Automating this process can reduce the labor intensity of the overall process. A sortation device identifies individual items on a conveyor system and is able to divert them to their proper location using a variety of discharge methods..
One of the strategic partners ABCO Systems is aligned with is EuroSort. In 2001, EuroSort emerged from a need for a solution to manage the growing number of irregularly shaped items requiring sortation in warehouses. The first EuroSort sorter design was the Split Tray Sorter, which quickly caught on in the industry. EuroSort learned from each installation of the Split Tray Sorter and the design was augmented and refined over time. With the rising demand for sortation, EuroSort continued to release new sortation solutions such as the Dual Split Tray, Push Tray, Twin Push Tray, Cross Tray, Sweeper, and Push Bar Sorters.
Let’s look at the EuroSort Push Bar Sorter. This sortation solution was first installed in 2004 and then re-introduced in 2019 after further cultivation of the technology. The Push Bar Sorter offers a wide range of sortable products, extreme layout flexibility, and easy scalability to allow for a fast ROI and a significant increase in productivity.
The EuroSort PushBar Sorter affords precise bi-directional sorting using an overhead push divert. This allows for the accurate discharge of a large variety of products into an extremely tight destination like an outbound carton or mailsack. The system is designed to be space-conscious and requires a minimum of maintenance.
The EuroSort Push Bar Sorter accurately sorts items from as small as a single business card or individual polybag up to a 30-inch carton at rates of up to 3,000 items/hour. The system is also becoming a reliable solution for linear sortation at a more affordable cost.
Let’s take a look at the benefits of the EuroSort Push Bar Sorter:
Modular Construction – The ultimate in flexibility!
Manual Induction Ease – Save money, reduce complications, and increase your flexibility with a machine that allows for manual induction.
No-touch Pack Out – The tightest discharge pitch in the industry enables the sorting of items directly into the outbound carton/tote/container with no secondary touch during pack out.
No Weld Framework – Easy installation, easy expansion, and superior modularity of your sortation system.
Smallest Discharge Pitch – Increased accuracy allows for a smaller discharge pitch and a denser sorter footprint.
Gentle Push Product Handling – Sorting your fragile items without damage!
Quiet As a Mouse Operation – Noise levels below 70db
Low Budget Friendly – High-quality automation without the high price tag.
Key Takeaways:
Automation does not replace human labor, it takes on the more tedious aspects of the distribution process
Automating the sortation of a diverse array of products can increase the accuracy and efficiency of your distribution
Sortation automation can be flexible and space efficient
Sortation automation solutions can be cost-effective and implemented without disruption to your workday or current processes.
Contact the ABCO Systems Team for more information on the sortation solution that is right for you.
Over the past several years, as warehouse automation has become a necessity rather than a luxury, companies of all sizes have started investing more in warehouse robots. Using automated robots helps to streamline how goods are sorted and shipped, increases productivity, and raises the stakes of the game for warehouses throughout the country.
As demand for warehouse automation continues to grow, warehouses big and small are looking into which robots make sense for their warehouse. At ABCO Systems, we want you to understand the different options for robots and which solution might help take your warehouse to the next level.
AMRs
What are AMRs?
AMR stands for Autonomous Mobile Robot — a self-contained machine that can be programmed to carry out a wide range of material moving activities.
An AMR does not need human supervision thanks to sophisticated sensors and cameras that it uses to see. This gives it the ability to detect if a human or obstacle is in the way and move out of the way accordingly which helps keep warehouses safe even while introducing automation.
What can AMRs do?
Transport and sort goods
Help with the picking process
Manage inventory
Avoid collisions with humans, objects, and fixed structures
Benefits of AMRs:
Increases efficiency and productivity by eliminating the need for workers to complete repetitive, physical tasks
Frees up employees to focus on more important tasks
Streamlines picking processes which reduces human error
Saves time, cuts costs, and increases productivity
Can work safely with humans
Smaller than other machinery including forklifts
Can obey programming instructions
Can be deployed in minutes with proper route mapping
Types of AMRs:
Picking and putting which picks up items and places them where they are needed
Inventory management to track SKUs in real-time and alert the need to replenish low stock
Transportation for bringing direct goods to their next stop
AMRs are dependable and can work for 12-15 hours before needing to be charged. A single robot can free up to two employees, allowing them to work on other more important jobs. If your team is constantly carting things around large areas, AMR technology will benefit your warehouse.
AGVs
What are AGVs?
AGV stands for Autonomous Guided Vehicle — an unmanned guided vehicle that completes automated repetitive tasks that help keep warehouses moving smoothly. AGVs move materials from one part of the warehouse to another, often delivered directly to processing lines via a predetermined path mapped by QR codes on the floor. By using an AGV, a warehouse is more likely to keep running smoothly rather than deal with delays due to waiting on humans.
What differentiates an AGV from an AMR is an AGV travels on a predetermined path and cannot make corrections to its path in real time.
What can AGVs do?
Transport raw materials
Deliver materials directly to production lines
Deliver materials without needing human interaction
Move materials to storage or retrieve items from storage
Benefits of AGVs:
Increases efficiency and productivity by eliminating the need for workers to complete repetitive, physical tasks
Frees up employees to focus on more important tasks
Streamlines picking processes which reduces human error
Saves time, cuts costs, and increases productivity
Can work safely with humans
Smaller than other machinery including forklifts
Can obey programming instructions
Types of AGVs:
Carts that move around the facility and carry materials
Tuggers which can pull carts with loads up to 50,000lbs
Forklifts that can move paper rolls, coils, and more
Unit-load that can move single products such as a pallet or bin
Heavy haul that can move machinery up to 250,000lbs
How to choose between AMR and AGV
AGVs have been a warehouse staple for decades and were first introduced in the 1950s. Until recently, they were one of the only options for automating the repetitive tasks of bringing goods from one place to another. However, with the introduction of AMRs, their status as the primary warehouse robot is being challenged.
AMRs are more sophisticated, flexible, and cost-effective. They are also more autonomous when maneuvering and can detect objects and move around them or stop. For example, if an AMR detects a human moving towards it is trained to get out of the way while AVRs follow predetermined tracks on the floor and cannot adjust their path, even to avoid hitting a person or machine.
5 Differences between AMRs and AGVs:
AMRs have better data collection than AGVs
AMRs are safer than AGVs because AMRs can move around objects and humans in their path while AGVs cannot
AMRs are more cost-effective than AGVs as it does not require changing the building infrastructure needed to create the predetermined paths AGVs use
AGVs have a simpler control system and sensors than an AMR
AGVs stick to their path while AMRs can become “lost” when crossing large expanses of floor space
We hope that this article was able to shed some light upon the differences between AGVs and AMRs. While Automation continues to become an integral part of warehouse operations, robotics may still feel like uncharted territory that is financially out of reach for many businesses. Remember that the cost of robotics is highly dependent upon many factors. As a Systems Integrator, ABCO Systems is at your service to help you navigate your way through the countless options in robotics and all other aspects of automation.
To learn more about if an AGV or AMR is right for your warehouse, or to set up a consultation to discuss your challenges and how we can offer solutions to fit your unique needs, CLICK HERE and an ABCO Systems Team member will put you in touch with the right team to make your dreams of Robotics a reality.
As we enter December, you may be thinking about automation, but is it too late to implement automation in time for the upcoming Holiday Season? We all want to be able to meet and exceed the needs of our customers as well as make the best use of our labor force but think that implementing automation at this stage would be way too difficult and costly. Think again.
ABCO Systems offers you an early holiday gift with our new white paper on 4 Easy Ways to Automate. Click the box below to download and learn how you can easily implement an automation solution now that is scalable for future growth.
To most people, the idea of automated labor seems like something out of the realm of sci-fi. With visions of Rosie the Robot dancing in our heads, it’s hard to believe we’re living in the future that so long seemed restricted to the realm of fiction.
And yet, these days, automated labor has become more common, and more practical, than ever before—and nowhere is this truer than within the distribution and fulfillment industries. Automation investment can make sure that your distribution center is prepared for the challenges of operating at peak profitability in the current market landscape.
As employers face issues of employee unreliability, high turnover, and increasing labor shortages through the distribution space, automation is more than just a future fantasy. It’s quickly becoming vital to commercial success in the here and now.
A closer look at labor scarcity
According to a recent report published by The Washington Post, over 43 million Americans quit their jobs over the course of 2021. Commonly called the “great resignation,” this wave of employee departures shows no sign of slowing. In fact, some employers report that resignation is currently at an all-time high.
So what’s the future of the great resignation? Expert predictions vary, with some stating that the trend will continue into 2023 and beyond. Other experts predict that more Americans are getting back to work—but that the attitude towards labor and willingness to walk away from a job that no longer feels rewarding will likely stay the same.
As demand for online shopping surges and e-commerce sales continue to become a preferred retail method for Americans throughout the United States, employees face increased hours and higher stress levels as they try to keep up with the growing demand.
The result? An increasingly unstable labor market that shows no signs of self-correcting, leaving employers facing higher costs and worse results. In fact, according to one study, as many as 73% of warehouse operators struggled to find adequate labor.
We need to face the facts: what was once a trend is quickly becoming a labor market norm, one that disproportionately impacts operators of distribution centers, warehouses, and other third-party logistics professionals, where staffing shortages are worsened by increasingly high turnover rates.
Automation: the wave of the future Automation may once have seemed like a sci-fi solution to the sector’s labor woes, but these technologies have increasingly become a critical aspect of the manufacturing and logistics world’s real-world operations. In fact, a study published in the Harvard Business Review indicated that within the next four years, the global warehouse automation market can be expected to double in value, with supply chain leaders describing warehouse automation as, …” One of their top three priorities for digital investment.” Workers cited by the study also expressed optimism, with many sharing their excitement for the potential of automation technologies to improve safety, increase speed and efficiency, and allow them to produce higher-quality work. The advantages of automating processes that were once performed by human labor is clear to employers who have struggled to maintain adequate staffing within their warehouses. Automation cuts down on your need to hire, making it easier to increase order accuracy, and productivity, and focus on reducing workplace injury for warehouse employees. Not only does automation reduce the need for labor, but it also makes work less demanding, reducing the turnover rate and leading to lower stress levels and a more positive work environment that encourages employees to stick around. These days, there are many forms of warehouse automation in common use. Companies use warehouse management systems to automate manual processes, inventory control, and data capture, supporting data analysis. Using this software in conjunction with technology such as sensors and robotics helps minimize the need for human labor, increasing efficiency and reducing costs. Making automation practical It’s no secret that warehouses and the fulfillment industry as a whole continue to be major drivers of change within the American economy. Around 1.5 million American workers are employed in the warehouse and storage sector, many of whom are ambivalent about the impact that the coming automation revolution may have on their careers. However, when approached correctly, automation can actually be a critical asset in supporting the fulfillment sector for both workers and employers alike. The key to making automation an asset? Communication and training at every step of the way. Automation can do a lot, but it still requires human intelligence and discernment to perform at its most effective level. Instead of framing automation as a threat to employees, employers should share the way that automation can make their lives better, and their jobs easier. Done correctly, automation takes the pressure off, handling all the most dangerous, difficult, and repetitively dull tasks, leaving workers free to think more creatively and focus on building their skill sets on a higher operational level. This need for training is apparent even to workers who are otherwise enthusiastic about the potential automation brings to their workspaces. As 35% of the warehouse workers interviewed in the Harvard study reported, workers fear that inadequate training resources will make it difficult for employees used to the old way of doing things to succeed in the new digitized, automated workspaces of the future. “I think the more the warehouse is automated, the better we’ll all perform,” said one warehouse supervisor cited by the study. “Robots will greatly diminish our workloads, reduce risks, and increase productivity. But if we don’t know how to handle them, they’re hardly going to do any good.” To assuage these fears, employers in the distribution and fulfillment space need to place a priority on training, communication, and open conversations with employees as they move forward into the coming automation revolution. Emphasizing the potential career growth possibilities moving towards automation offers will allow workers to envision their longer term prospects working within the fulfillment sector, helping get them on board to perform the tasks necessary for accessing the full potential of automation technology. As warehouse work continues to be a mainstay of the global economy, automation technologies can make a major positive impact. When human capital combines with the power of automation, anything is possible.
When it comes to supply chain, every business has its own way of doing things. Old habits – like completing inventory counts, picking, packing, and doing things manually – die hard. As businesses struggle to keep up with companies like Amazon, they may be wondering how supply chain automation – the process of replacing repetitive tasks with automated systems – is affecting an industry that is changing before its eyes. At ABCO Systems, we want to share our knowledge on how supply chain automation is affecting the warehouse, distribution, and fulfillment center industry.
Lowering costs and increasing productivity
For those who work in the warehouse arena, automation is what’s on everyone’s minds. With the current labor shortages, automation is a way to subvert those challenges and meet them head-on. Currently, over 80% of warehouses have no automation at all[1]. That doesn’t mean everything is by hand, it just means that while 15% of warehouses are being mechanized, only 5% use sophisticated automation equipment.
As labor shortages continue, warehouse operators are looking for ways to use automation technology to increase efficiency and reduce the human labor needed to keep a warehouse running smoothly. According to a study, a warehouse spends around 50% to 70% of its warehousing budget on labor. By moving from human labor to automation, experts expect over the next three years to see an increase in productivity by between 25% and 70% and a reduction in logistics costs between 20% and 40%[2].
As warehouses decide to adopt automation systems, they can rest easy knowing that many of these systems are already proven. ABCO Systems believes in the use of conveyors to facilitate most of the operations associated with manufacturing, distribution, and warehousing facilities. Learn more about our Automation systems here.
2. Eliminating safety risks
Keeping warehouse employees safe is an important task for any company. The US Bureau of Labor Statistics reported an average of 16 fatalities every year and a reported injury and illness rate of 5 out of every 100 warehouse and storage workers[3]. Additionally, worker injuries cost businesses billions of dollars every year.
With the labor shortages, workers can find themselves in even more dangerous situations since teams have to work harder to make up for the job vacancies. Automation can help reduce safety hazards including lifting injuries, falls, and fatigue. The longer a worker is on duty, the larger their risk of injury[4]. Implementing automation techniques that allow workers to take longer breaks or work shorter hours will also help to reduce the number of injuries.
Having machinery do the heavier lifting keeps workers away from some of the more dangerous tasks and also away from the more repetitive tasks that can lead to chronic back or shoulder problems. According to OSHA and the US Bureau of Labor Statistics, in 2019 tools and equipment caused 186,100 injuries that required workers to take days off to recover[5]. Implementing proper systems and technology helps achieve safety goals while also increasing efficiency.
3. Higher customer satisfaction
In the end, companies want happy customers. Achieving that goal means getting the correct products out the door as quickly as possible and to the correct person.
Improved productivity with fewer errors helps keep warehouses competitive. An automated warehouse is more efficient and productive. According to a study by Deloitte which surveyed more than 400 executives in manufacturing, “79 percent of organizations with superior supply chain capabilities achieve revenue growth that is significantly above average”. Implementing automation can help drive down costs and reduce processing times giving businesses an edge against their competitors by delivering faster, more accurate service.
Contact us to see how ABCO Systems can help you increase efficiency in your space and processes with warehouse automation solutions.
