ABCO Systems

New Year Resolution – Smart Strategies for a Smart Warehouse

Jan 2, 2024 | 3PL, ABCO Systems, AGV, AMR, AS/RS, Automation, E-commerce, Goods-to-person, order fulfillment, Robotics, space optimization

Picture this – it’s a crisp morning in January, and you stand at the entrance of your warehouse, eager to kick off another year of growth for your business. The dawn of a new year is the perfect opportunity to reflect on past achievements and set the stage for transformative changes. As the world of logistics and warehousing continues to evolve at a rapid pace, it is our firm belief that the resolution for 2024 should be to embrace smart strategies for a smarter warehouse. Let’s delve into the 4 key trends, backed by compelling statistics, that are reshaping the landscape for warehouse managers, logistics professionals, 3PL managers, Ecommerce Managers, Fulfillment Managers and many others engaged in supply chain.

Embracing Automation and Robotics

In a recent study conducted by Statista, the global warehouse automation market was valued at over 23 billion U.S. dollars in 2023. It is expected that the market will grow at a CAGR of about 15 percent in the following years and reach the size of 41 billion U.S. dollars in 2027, a testament to the accelerating demand for streamlined operations. As we bid farewell to static storage technologies, the emphasis on automation and robotics becomes paramount. By integrating Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) into your warehouse fleet, you not only boost efficiency but also enhance the overall safety of your team. These technologies offer a dynamic solution for material handling, allowing for swift adaptability to changing demands.

Picking Technologies that Redefine Speed and Accuracy

Accurate and speedy order fulfillment is the cornerstone of customer satisfaction, and in the evolving landscape of ecommerce, these two aspects of supply chain have become non-negotiable. According to a report by McKinsey, warehouses equipped with advanced state-of-the-art picking technologies experience a 20% increase in order accuracy. Imagine the impact on your bottom line when every package is delivered correctly the first time. Modern solutions, such as advanced Pick-to-Light technology and Pick/Put Walls, are reshaping the picking process, reducing errors, and ensuring your customers receive their orders promptly and accurately.

Responsive Warehousing in the Age of Ecommerce

In the era of one-click shopping and next-day delivery expectations, responsiveness is a key differentiator for warehouse managers. A study by Deloitte highlights that companies with highly responsive supply chains grow revenue 10% faster and reduce costs by 30% more than their peers. This New Year, consider the implementation of Automation and Robotics, combined with appropriate Warehouse Execution Systems (WES) that can seamlessly integrate with your existing infrastructure, optimizing task prioritization, resource allocation, and order fulfillment. Responsive warehouses not only meet customer expectations but also stay ahead of market trends.

Optimizing Footprint and Reducing Costs

An increase in order volume or expansion of operations and SKUs, often prompts the need for more warehouse space. However, since warehouse space has been at a premium for some time now, the resolution for 2024 is to optimize within your existing footprint. By reassessing and redesigning your current layout, as well as deploying new solutions like high-density automated storage systems, you can maximize vertical space and reduce the need for extensive horizontal expansion. This strategic approach not only curtails costs associated with additional square footage but also enhances overall operational efficiency.

Conclusion

As you embark on this journey to build a smarter warehouse in 2024, remember that the right partner can make all the difference. ABCO Systems is a material handling integrator company with a proven record of incorporating cutting-edge automation, robotics, and picking technologies, thereby empowering your team to achieve higher accuracy, responsiveness, and growth – all within your existing footprint. Make this New Year resolution not just a commitment to change but a promise to revolutionize your warehouse for sustained success. Here’s to a year of smart strategies and smarter warehouses!

A Complete Guide to Mezzanines & Catwalks

Oct 31, 2023 | 3PL, ABCO Systems, Automation, Conveyor, E-commerce, Mezzanine, order fulfillment, Permit Facilitation, space optimization, Storage, Supply Chain

People tend to call any elevated platform a “mezzanine” these days, but that can be a big mistake, especially in the permitting process. The terms equipment (or work) platform and mezzanine both refer to structures that create an intermediate floor. There are some important nuances however, and whether you call a structure a mezzanine or an equipment platform can have serious implications when it comes to the ease of getting building permits, as well as construction costs. The impact on your taxes and depreciation will also vary depending on the term used.

What’s a warehouse mezzanine? What’s a work platform?

A mezzanine is a relatively permanent structure that is typically installed within an existing building or industrial facility. It is a raised platform that is constructed above the ground floor, typically supported by existing columns or posts, and is designed to provide additional floor space for storage, office space, or other purposes. Mezzanines can be designed and installed in a wide range of configurations to meet the specific needs of the facility.

A warehouse platform, on the other hand, is a raised platform that is typically designed and constructed as a stand-alone structure with the aim to provide additional floor space for storage, manufacturing, or other industrial processes. Warehouse platforms are generally larger and more robust than mezzanines and are designed to support heavy loads and equipment.

The pivotal differences: Is it part of the facility? What will you be using it for?

The critical distinction lies in the platform’s association with the facility. It hinges on whether the authorities classify the mezzanine as an integral part of the building or as capital equipment. Numerous newly constructed buildings incorporate what they refer to as “mezzanine levels” into their structural design. When a platform is deemed an inherent component of a building rather than capital equipment, it may be subject to compliance with building codes, restroom requirements, accessibility standards, and may influence tax rates and depreciation schedules.

Another key factor is the intent – It is imperative to ensure that building permit authorities and regulatory bodies fully grasp the purpose and design of the structure. To achieve this, it’s advisable to refer to your mezzanine project using designations such as “work platforms,” “elevated platforms,” “storage platforms,” “equipment platforms,” etc. These terms offer greater precision and clarity compared to the overly encompassing and sometimes imprecise term “mezzanine.”

This can impact your taxes since in some states mezzanines are considered part of the square footage of the facility, while platforms aren’t. This can seriously impact on property taxes every year, as well as depreciation deductions since capital equipment depreciates differently.

Practical Applications

Combined with various warehouse automation equipment, mezzanines can provide a great option to grow in your existing footprint by optimal usage of the cube in a variety of applications:

Storage
Production
Offices/Administrative Space
Equipment positioning
Picking Modules

Utilizing the vertical space with a mezzanine means that you need to move material between levels without creating bottlenecks. This means that you will need automation equipment to move materials up and down between levels. The technology for this purpose can be grouped into 3 general categories:

Spiral Conveyors. This type of conveyor has a small footprint and provides excellent throughput, usually for handling of cartons, totes and less than pallet loads.
Incline Conveyors. Though it is less space efficient than spiral conveyors, the incline conveyor is a very economical and robust option for automated handling of a wide variety of loads.
Vertical Lifts. These sturdy pieces of equipment have a small footprint and are particularly effective in setups where heavier loads or bulky items need to be lifted.

In a warehouse environment one of the most important advantages of elevated platforms is their high-density storage application. Generally speaking, these can be classified in 3 groups:

Rack Supported Mezzanines. These mezzanine configurations combine high bay pallet racking with walkways between the rack. The racks can be fitted with carton flow for dense order picking and mixed storage of pallets. Rack supported mezzanines allow a multitude of options for customization and are a very economical choice for vertical space utilization.
Shelving Mezzanines. Applied in configurations for handling small items such as parts or tools. This type of platform maximizes the number of storage bins, allowing for a great number of SKUs to be organized in a concentrated space while remaining easily accessible for pickers.
Multilevel Pick Modules. These highly customizable solutions integrate various storage solutions that enable a very efficient movement of product by combining elements of mezzanines with conveyors, spirals, pallet/carton flow, static racking and shelving, pick/put to light etc. They are specially designed with zoning and provide significant cost savings for broken pallet, full-case or open-carton picking.

How we can help you

The choice between a mezzanine and a warehouse platform ultimately depends on the specific needs of the facility and the goals of the business. As a true systems integrator, ABCO Systems also has a vast experience in designing and delivering these kinds of solutions, including a very efficient navigation of the permitting process. Reach out to us today to get started!

Choosing the Right Conveyor System for Your Warehouse

Oct 24, 2023 | 3PL, ABCO Systems, Automation, Conveyor, cost reduction, E-commerce, order fulfillment, Sortation, space optimization

Conveyor systems have become a staple of modern warehousing operations. These mechanical marvels play a pivotal role in efficiently and swiftly moving goods, enhancing productivity, and ensuring seamless and safe material handling. Whether you’re dealing with a large-scale distribution center or a smaller storage facility, selecting the right conveyor system is a critical decision. In this blog post, we’ll explore the types of conveyor systems and discuss their key benefits, shedding light on their technology and practical applications.

Key Benefits of Conveyor Systems

Productivity and Speed of Movement

Conveyor systems accelerate the movement of goods within a warehouse, resulting in faster throughput and order fulfillment. They maintain a consistent pace, minimizing bottlenecks and ensuring a smooth flow of products.

Efficiency and Flexibility

Conveyor systems enhance warehouse efficiency by automating material handling processes thereby reducing labor costs. They also offer flexibility in routing, sorting, and handling various items, enabling quick adaptations to changing operational needs.

Safety

Safety is paramount in any warehouse setting. Conveyor systems are designed with safety features, reducing the risk of accidents and injuries associated with manual handling. They help maintain a safe working environment for employees.

Types of Conveyor Systems

Belt Conveyors:

Technology: Belt conveyors use continuous belts made of rubber, plastic, or fabric to transport items. They run on pulleys or drive units.
Application: Ideal for transporting bulk materials, packages, and irregularly shaped items. Commonly used in distribution centers, airports, retail, and manufacturing facilities.

Roller Conveyors:

Technology: Roller conveyors use cylindrical rollers to move items. They can be motorized or gravity-based, providing flexibility in operation.
Application: Suited for light to medium heavy items. They are commonly found in distribution centers, warehouses, and assembly lines.

Chain Conveyors:

Technology: Chain conveyors use interlinked chains to move products. They can handle heavy loads and are powered by electric motors.
Application: Ideal for moving pallets or heavy products in warehouses and distribution centers, as well as in industries like automotive, construction, and food processing.

Slat Conveyors:

Technology: Slat conveyors consist of slats or plates connected to a chain. They are designed for handling heavy and temperature specific items.
Application: Commonly used in heavier industrial facilities for transporting heavy or hot items.

Overhead Conveyors:

Technology: Overhead conveyors use a track system with suspended hooks, carriers, or trolleys to move items above the workspace.
Application: Suitable for painting lines, assembly lines, and storage facilities, particularly in cases where floor space is limited.

Key Considerations when Choosing a Conveyor System

When selecting a conveyor system for your warehouse, it’s crucial to consider a range of factors that will impact its effectiveness. Here’s a list of key considerations in bullet point format:

Type of Goods/Materials to be Handled

Different conveyor systems are designed to handle specific types of goods. Consider whether you’re transporting boxes, pallets, irregularly shaped items, or even delicate or fragile materials. The choice of conveyor should align with the nature of your products.

Throughput

Determine the volume of items your conveyor system needs to handle within a given timeframe. High-throughput operations require robust systems to prevent bottlenecks, while low-throughput setups may benefit from more cost-effective solutions.

Available Space

The layout of your warehouse and the space available for conveyor installation are critical. Some conveyor types may require more floor space, while others can utilize vertical space effectively. Ensuring that the system fits seamlessly within your facility and optimally uses the available vertical space is very important.

Budget and ROI

Establish a clear budget for your conveyor system. Costs may vary significantly depending on the conveyor type, technology, and additional features. Balancing your budget with your operational needs is essential. On the other hand, automated systems reduce the need for manual labor, so calculating the ROI on your investment provides insights into the overall benefits of the implemented solution.

Scalability to Cover Long-Term Goals

Consider the future of your business and warehouse operations. A conveyor system should be scalable to accommodate growth and evolving requirements. Analyze the ease with which you can adapt, expand, modify, or reconfigure the system to meet long-term goals.

By carefully evaluating these considerations, you can make an informed decision and select a conveyor system that aligns with your specific needs, maximizes efficiency, and supports your warehouse’s growth and success.

At ABCO Systems, we understand the significance of choosing the right conveyor system for your warehouse. With decades of experience in consultancy, design, and installation of conveyor systems of all types and sizes, we’ve helped countless businesses achieve efficient and seamless material handling. But our commitment doesn’t end there. We go the extra mile by offering comprehensive preventative maintenance and servicing program to protect your investment and optimize your operations for years to come. Reach out to us today to explore the ideal conveyor solution for your specific needs and let ABCO Systems be a trusted partner in your journey to a more efficient and productive warehouse!

Revolutionizing Order Picking with Pick Module Automation

Sep 27, 2023 | 3PL, ABCO Systems, AGV, AMR, Automation, Conveyor, E-commerce, order fulfillment, Sortation, third party logistics

In the world of order fulfillment, precision and speed are paramount. Every second counts, and every error can be costly. That’s where cutting-edge Pick Modules come into play, revolutionizing the way businesses handle their picking operations. In this blog post, we’ll dive deep into the world of Pick Modules, unveiling how they streamline order picking, increase efficiency, and make the entire process painless.