Schemes of Automatic Warehousing

The most commonly offered schemes or tools of automatic warehousing for organizations to reduce cost as well as speed product movement, include Robots, AS/RS, layer-forming palletizes, forklifts, conveyors, transfer cars and RFID, amongst others.

Robots

Robots are very effective when it comes to using them in a material handling system. They are programmed such that not only the operator can make desired adjustments in its settings, but also add patterns as per the requirements. The programming is based on palletizing primarily, as well as for de-palletizing / re-palletizing layer, to automate creating rainbow pallets – various layers of SKUs on each pallet.

AS/RS

As we studied earlier, Automated Storage and Retrieval Systems (AS/RS) – the computer-controlled systems can be considered to avail compact, high density systems that help in saving lot of floor space in the facility. This also saves labour, is 99.9% accurate and prevents the products/materials from being damaged. Besides, AS/RS also offers instant access to wealth of information that can be retrieved by logistics and warehouse managers through web links itself.

Layer-forming Palletizer

These are generally used for high speed applications in sync with handling bags in the wake of importance of pattern quality. While a robot cannot be used for squaring each layer before stripping it onto the pallet in case of handling bags, a layer-forming palletizer can. For a warehouse with fast rates and only one line, layer-forming palletizer works best. However, the trend today is more towards using robots, because of its multiple production lines handling capacity.

Forklifts

Forklifts are commonly used in automated warehouse systems for truck loading that also use counter-balanced trucks to facilitate external product flow, equipped with RF equipment that allows the operator to communicate with the Warehouse Management System or WMS.

Conveyors

Conveyors do not need electric controls to achieve zero pressure accumulation, but a motor for maximum lengths of 100 feet (20 zones). They are considered cost effective, in the sense that only a two HP motor is required for up to 100 feet.

Transfer Cars

Transfer cars can be used to combine multiple pickup/drop off locations with 1-2 in-feed lines into an AS/RS, such as palletizing lines. The Programmable Logic Controller or PLC (a small computer) takes care of control over the machinery, and is programmed such that it can respond to conditions detected by sensors.

RFID

RFID, as we have read before, can be used at the pallet level, unit level or case level. For medium or long-term trend, RFID tags should be implemented at the unit level, to track every single consumer purchase transaction. RFID readers can easily be integrated into any form of AS/RS for pallet as well as product identification on a pallet; the data thereof can be then used subsequently throughout the supply chain management. RFID is one another scheme of automated warehouse system that facilitated identifying a product without any visual reference attached to it.

Pallets

Pallets made of plastic are very much in fad. Being more automation-friendly, they are easy to move on conveyors, yet expensive than wooden pallets. However, in case of a captive system, they are more effective and economic for a long period. Plastic pallets are also used in food applications, where cleanliness is the priority.