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.

The Pick Module Advantage

Pick Modules are multi-tiered systems designed to optimize order picking in warehouses. They are carefully engineered to maximize both vertical and horizontal space, creating a highly organized environment where items are readily accessible. Let’s explore how they elevate order fulfillment:

1. Vertical Optimization: In warehousing, vertical space is often underutilized. Pick Modules change the game by stacking inventory vertically while maintaining accessibility. This vertical optimization drastically increases storage capacity, making it possible to store more SKUs in a smaller footprint. This is achieved through the clever integration of conveyors that efficiently transport items to different tiers, effectively utilizing every available inch of space.

2. Speed and Efficiency: Pick Modules are strategically designed to minimize travel time for pickers. Products are stored in a way that ensures fast and efficient retrieval. Conveyors, pick-to-light technology, and pick walls work in harmony within these modules. Conveyors seamlessly transport items to the picker, while pick-to-light systems guide them to the precise location of the required products. Pick walls, equipped with compartments and technology, further aid in streamlining the process. These technologies collectively reduce the distances pickers need to traverse, order fulfillment speeds skyrocket, enabling you to process more orders in less time.

3. Customization: One of the most significant advantages of Pick Modules is their adaptability. They can be tailored to match the specific needs of your products and order profiles. Whether you’re dealing with small, fast-moving items or larger, slower-moving goods, Pick Modules can be configured to accommodate them all. This customization extends to the integration of Automated Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs) for tasks such as material transport, ensuring a seamless flow of items within the module.

4. Scalability: As your business grows, so does the demand for efficient order fulfillment. Pick Modules are inherently scalable, allowing you to expand your picking capacity without needing to relocate or rebuild your warehouse. This flexibility ensures your operation can evolve with market demands. AGVs, in particular, are a versatile addition, capable of adapting to changing workloads and efficiently moving products in and out of the module.

5. Improved Accuracy: Inaccurate picking can lead to costly errors. Pick Modules are designed to enhance picking accuracy. Products are organized logically, and pickers are guided to the correct locations through technologies such as pick-to-light. This reduction in human error ensures that the right products are selected, reducing the likelihood of mistakes.

6. Ergonomics and Safety: Employee safety is paramount. Pick Modules are often equipped with features like ergonomic workstations and safety measures, reducing the risk of accidents and minimizing strain on workers. This extends to the collaboration between pickers and AMRs or AGVs, where safety systems are implemented to ensure smooth interactions.

The Future of Order Fulfillment

In an era where customers expect swift and error-free deliveries, Pick Modules have emerged as a game-changer for order fulfillment. These systems seamlessly blend advanced technology such as conveyors, pick-to-light systems, pick walls, AMRs, and AGVs with vertical optimization and customization to create a painless, efficient, and future-proof picking process.

By investing in cutting-edge Pick Modules equipped with these technologies, businesses are not only meeting the challenges of today but also preparing for the demands of tomorrow. Contact us today to explore possibilities to get a well-designed Pick Module system in place. By working with us, you’ll not only enhance the speed and accuracy of your order fulfillment but also pave the way for satisfied customers and continued growth.

Maintenance Tips to Ensure Uninterrupted Material Flow

Sep 13, 2023 | 3PL, ABCO Systems, Automation, Conveyor, Maintenance, New Warehouse

The rhythmic heartbeat of any warehouse, conveyors serve as the vital arteries that keep material flowing seamlessly. But like any lifeline, these systems require proper care and attention to ensure uninterrupted operations. In this essential blog post, we’re diving into the world of conveyor maintenance, uncovering tips and strategies to keep your material flow pulsating at its best.

The Backbone of Efficiency

Conveyors are the unsung heroes of efficient material handling, swiftly transporting items from point A to point B. However, neglecting their maintenance can lead to unexpected breakdowns, costly downtimes, and disruptions in your supply chain. By implementing a proactive maintenance plan, you not only extend the lifespan of your conveyors but also enhance overall warehouse efficiency.

Routine Inspection: The First Line of Defense

Regular visual inspections are the cornerstone of conveyor maintenance. By routinely examining belts, rollers, bearings, and other components, you can identify signs of wear and tear early on. Addressing minor issues before they escalate can prevent larger breakdowns that require extensive repairs.

Lubrication: A Little Goes a Long Way

Proper lubrication is the lifeblood of conveyor systems. Regularly lubricating moving parts reduces friction, minimizes wear, and ensures smooth operation. Be sure to use the appropriate lubricants for different components and maintain a schedule for reapplication.

Tighten the Bolts and Belts

Conveyors endure constant vibrations and movements, which can gradually loosen bolts and belts. Periodical checks and tightening of all fasteners prevent components from becoming dislodged. Similarly, ensuring that belts are properly tensioned avoids slippage and maintains optimal traction.

Cleanliness and Debris Management

Cleanliness is more than just aesthetics; it’s essential for conveyor functionality. Debris accumulation can hinder movement, damage components, and even cause blockages. Regular cleaning of the conveyor system, including belts, rollers, and the surrounding area therefore is very important as it prevents foreign objects from causing disruptions.

Electrical and Control System Checks

Conveyor systems often rely on complex electrical and control systems. Regular inspections and tests of these components ensures they’re functioning correctly. Faulty sensors, misaligned photo eyes, or malfunctioning motors can lead to operational interruptions.

Training and Documentation

Equipping your maintenance team with the knowledge and training necessary to perform routine maintenance tasks effectively can go a long way. At ABCO Systems, we create a comprehensive documentation system that outlines maintenance procedures, schedules, and troubleshooting guides. This empowers your team to address issues promptly and effectively.

Partnering with Professionals

While proactive in-house maintenance is vital, the value of partnering with conveyor system professionals such as ABCO Systems should not be underestimated. Regular inspections by experienced technicians can identify potential problems that might be overlooked internally. Scheduled maintenance from experts can provide peace of mind and extend the longevity of your conveyor systems.

Implement Your Well-Structured Maintenance Plan

Conveyors are the lifeline of your material handling operations, and their maintenance is a non-negotiable responsibility. By implementing a well-structured maintenance plan that encompasses routine inspections, lubrication, cleanliness, and expert support, you’re ensuring the uninterrupted flow of materials that keeps your supply chain beating. In the grand scheme of warehouse operations, the harmony of conveyor systems can only be maintained through consistent care, attention, and the understanding that a smoothly running conveyor network is the backbone of your operational success.

Click here to reach out to us at ABCOSystems.net today to learn more about our Preventive Maintenance Programs!

Driving Innovation: Autonomous Mobile Robots (AMRs) in Warehousing

Sep 7, 2023 | 3PL, ABCO Systems, E-commerce, Robotics

In the ever-evolving landscape of warehousing and distribution, a new workforce is emerging, one that doesn’t require breaks, vacations, or even sleep. Welcome to the era of Autonomous Mobile Robots (AMRs), where innovation meets efficiency in the realm of material handling. In this blog post, we explore the rapid rise of AMRs and their transformative impact on modern warehousing.

Unshackling Productivity

AMRs represent a paradigm shift in how goods are moved within warehouses. These intelligent robots are designed to autonomously navigate through dynamic environments, adapting to changes in real time. By offloading routine tasks such as material transport, picking, and even packing, AMRs liberate human workers from physically taxing and repetitive activities. This newfound efficiency translates into higher productivity and an opportunity for employees to focus on value-added tasks that require human intuition and creativity.

Seamless Integration

One of the defining features of AMRs is their ability to seamlessly integrate into existing warehouse infrastructures. These robots do not require dedicated paths or extensive modifications to the facility. Through advanced sensors, mapping technology, and AI-driven algorithms, AMRs effortlessly navigate through aisles and shelves and even interact with human coworkers, ensuring a harmonious collaboration between man and machine.

Flexible Adaptability

Warehouses often experience fluctuations in demand, seasonal peaks, and evolving inventory patterns. AMRs thrive in this dynamic environment. Their adaptability allows them to be reprogrammed or reconfigured swiftly to accommodate changes. Whether it’s scaling up operations during high-demand periods or rearranging workflows due to shifting priorities, AMRs offer the flexibility that traditional fixed automation systems struggle to provide.

Enhanced Accuracy and Data Insights

The integration of AMRs isn’t just about physical tasks; it’s also about data acquisition. These robots are equipped with various sensors that enable them to collect and transmit valuable information about inventory levels, traffic patterns, and even facility conditions. This real-time data empowers warehouse managers to make informed decisions, optimize routes, and improve overall operations.

Safer Work Environments

Safety is a main concern in any warehouse setting. AMRs are designed with a multitude of safety features, including collision avoidance technology, emergency stop mechanisms, and the ability to adapt their behavior in response to human presence. By taking on physically demanding and potentially hazardous tasks, AMRs contribute to a safer work environment for human employees.

Embracing the Future Today

The rise of Autonomous Mobile Robots heralds a new chapter in warehousing history. These innovative machines are not just about efficiency; they’re about reshaping the way we think about labor, collaboration, and the potential of automation. As businesses continue to search for ways to streamline operations, enhance accuracy, and stay agile, AMRs offer a compelling solution that combines cutting-edge technology with tangible benefits. Join us in exploring the present and future possibilities of AMRs and witness how they are driving innovation in the heart of warehousing operations.

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