Above: workers in a distribution center putaway aisle with flow and bulk storage accessibility. Picking aisles are left clear as the system is replenished. Photo credit: Unex Manufacturing.

Putaway, which is the methods and processes that occur between receiving inventory and that inventory resting in storage positions in a warehouse, may have more impact on the performance of order fulfillment or warehousing operation than most anything else.

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In this new age of Covid-19, facilities all across the globe are working within ever-changing restrictions and prioritizing employee protection while keeping operations moving forward. Social distancing is a key component of this within any building, and those tasked with monitoring and implementing distancing within a workforce must create new ways to combat the spread. This challenge is tough to work within even the smallest of offices, let alone a large warehouse or distribution center. Reducing employee contact while maintaining thriving production is not easy, and requires continued vigilance and creativity.

When considering options for increased or maintained social distancing, utilizing an automated storage and retrieval system (ASRS) is a great option to help prepare your facility for the coming waves and for the automated future that lies on the horizon.

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As we’ve discussed automating anything as complex as a large scale material handling process has risks, but there are ways understand the outcome better in advance and reduce any risks. It’s always good to have more data, and simulation plays into that scenario by giving you a view of what key systems, technology and process will interact in your system, with your loads.

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Automation can work wonders. It reduces costs, increases throughput, curbs errors and increases safety. The costs of automation are declining while the effectiveness of computer, vision and scanning systems are improving. Automation helps you reduce repetitive actions — the kind that adds no value. The common perception is that automated facilities are dark, free of people and full of robots, but the reality is that automation comes in many forms, ranging from picking systems like pick-to-light to automated conveyors to goods-to-person systems and much more.

For all these benefits, you want to understand the potential problems with any automation project in advance so you can avoid them as you move forward.

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For high-volume pallet storage and retrieval operations, dynamic rack systems like pushback, drive-in or pallet flow allow maximum storage in a given area, but each have their limitations. In some instances, a pallet shuttle system may suit the needs of many operations. The costs and limitations are different for each storage method, as shown below.

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Each day brings new challenges and new considerations for warehousing, distribution and manufacturing operations in the age of Covid-19. One of the chief aspects of this “new normal” is the human element in your business. It’s shut down some operations, and crimped many others. For certain industries, demand has skyrocketed.

Automated solutions have the ability to help you weather the storm — or prepare for the next wave.

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In this new age of warehouse or facility labor shortage, more and more companies are turning to automation and robotics to help fill in the gap and increase productivity as well. With e-commerce showing no signs of slowing and innovative supply chains being rewarded, you can bet that companies embracing this new dawn are showing better ROI and efficiency. One aspect of adopting robotic help for your warehouse to review is that of safety. While the overall safe environment you provide to your operations is crucial, when adding robotics or automation to the mix it requires a new set of ideas and priorities to ensure your workers and ‘bots can coexist.

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As the progression of baby boomer retirees continues–at a blistering pace of 10,000 each day–all industries are feeling the pressure to attract the younger generation. Not only is this need growing, but in terms of keeping up with the faster pace of business, it’s paramount. Warehousing is no different and faces the tough task of keeping millennial (and younger) workforces interested in walking through its doors for the long haul.

Just how do warehouse operators attract qualified hires from the millennial generation? What are some ways not only to bring in these employees–but retain them?

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Material handling installations can be complicated by nature.

Shipments are coming from multiple sources, arriving at different times. Subcontractors from electrical installers to controls to cleaning crews must be coordinated. Layouts and concepts must be implemented on time, even as deadlines change while issues are being resolved. At the end of the process, the system must be commissioned and the people who will work in it trained. Maintenance and spare parts will be dealt with.

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Return-on-investment is critical to automation projects, but justification isn’t straightforward. If you’re trying to convince management to make capital improvements to your operation, a smart, accurate and succinct ROI summary can work wonders. Let’s dive into some methods you can use to understand what to do — and what you can’t quantify.
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