Storage optimization specialists

Automating processes often means increasing efficiency, but we should never forget that efficiency requires the continuous management of the processes and machinery involved in automation. Thus, automation also means maintenance.

Those who manage production, warehouses and related processes are always faced with the choice between:

  • Reactive or corrective maintenance that involves repairs only after a malfunction or failure
  • Preventive maintenance, that is, planned or scheduled maintenance activities which often involve the replacement of parts to prevent unexpected failures and long shutdowns.

In practical terms, the impact of maintenance on productivity should never be overlooked. The percentage of lost production varies from 5% to 20% for reactive maintenance, which involves the sudden interruption of production and the implementation of measures whose duration is difficult to estimate in advance.

Production line downtime costs manufacturers about €45 billion per year and almost half of those losses are due to technical failures of machinery (source: Kainet).

But how is it possible to calculate maintenance costs and determine the best approach to this issue for a company?

Maintenance costs are divided into two macro categories:

Own costs:

  • Direct costs: the most common of these are the manpower necessary to carry out the servicing and/or repair of machinery in addition to those relating to the purchase of materials and spare parts.
  • Indirect costs: these include costs relating to resources not directly involved but still impacted, as well as equipment, systems and services.

Induced costs: these are costs relating to downtime and failures that lead to production interruptions, errors, delays and are therefore difficult to predict and quantify.

Maintenance in the Industry 4.0 era

Industry 4.0 is changing everything: there is lots of talk about IoT (Internet of things), Cloud and Machine Learning but what impact do they have on the management and determination of the type of maintenance necessary for machinery?

Thanks to new technologies, it is possible to equip machines with sensors and systems that efficiently monitor what is happening in the device/system, analyze it, and report it in real time.

They have the ability to identify the relevant data, make diagnoses, and continuously capture data during the operation of the machine.

Data collection is combined with mathematical algorithms that enable the detection of anomalies before a breakdown as well as the reporting of real-time information on the state and performance of the machinery itself.

PREDICTIVE MAINTENANCE is closely related to this context.

That’s right. The continuous check-up of machinery and systems and the collection of data within them facilitate the monitoring of all relevant parameters in order to be able to intervene before the fault occurs, therefore, before unexpected downtime. The procedure is really simple: thanks to the ability to continuously monitor, collect, and process data, when any deviation is detected, it is signalled before significant wear or breakdown of a given part occurs.

Predictive and proactive maintenance: how to implement it

To make predictive maintenance possible, and implement it, two pillars of Industry 4.0 are extremely useful: MACHINE LEARNING and BIG DATA.

As suggested by the word itself, Machine Learning is the ability of machines to learn automatically from a certain experience. It includes techniques and algorithms closely tied to statistical calculation which facilitate continuous and stable improvement as the data processed increases.

This proliferation of information in the system generates large volumes of data, that is, BIG DATA for the production, maintenance and management of the production chain that comes from:

  • Programmable Logic Controllers (PLCs)
  • Supervisory Control Systems and Data Acquisition (SCADA)
  • Human Machine Interfaces (HMI)
  • IoT devices or IT systems in different business areas.

Thanks to these computational systems, it is possible to implement predictive maintenance 4.0 and prevent faults, problems, and unexpected events before they become a problem precisely because they can be anticipated, avoiding machine breakdowns or downtimes.

Therefore, predictive maintenance is a real opportunity for everyone to improve processes and minimize their own and induced maintenance costs.

Predictive maintenance is all about efficiency.

Article source modula.eu


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MODULA Automated Storage Systems

Storage optimization specialists

Modula automated storage systems can make up for labour shortages in the logistics world, in fact they solve many of the problems that cause them. In particular, according to ManpowerGroup’s MEOS Global Report, 75% of companies in the sector struggle to find qualified personnel for vacant positions.

This figure, which is very clear in itself, becomes even more significant when compared to that of the previous year, when it was 69%. We can conclude that:

  1. The shortage of skilled labour for the sector is an irreversible trend that logistics companies and supply chain companies, in general, have to deal with in order to remain competitive and efficient.
  2. Demand for labour in the sector tends to increase, mainly due to the growth of online trade.

On the other hand, working in warehouse logistics is still perceived as a strenuous, dangerous and repetitive job, and is therefore unattractive to the younger generations who are hardly interested in it and therefore do not acquire the necessary skills.

A storage automation system is undoubtedly one of the solutions capable of meeting these two needs:

  • increase staff satisfaction and consequently the attractiveness of the sector
  • mitigate the effects of labour shortages.

Let’s take a look at how Modula’s products – automated storage systems, picking solutions and robotic applications – help mitigate the negative effects of labour shortages in the supply chain and logistics sector.

Improved warehouse logistics management thanks to Modula’s Warehouse Management System

Companies can limit their labour requirements by deploying their current workforce more rationally while optimizing processes, procedures and the time spent on each operation. This can be done with the support of warehouse management software. Modula’s Warehouse Management System allows efficient, real-time management of the warehouse and offers numerous other advantages, since:

  • It is quick and easy to set up, all you need is a PC
  • It can be used with both traditional warehouses and automated storage systems
  • It integrates seamlessly with ERP, DMS, MRP and other business systems, enabling the exchange of accurate and timely information
  • The interface is simple and intuitive and does not require specialized skills in addition to being easy to learn
  • The system streamlines the operators’ procedures and movements, making their work smoother.

Modula WMS can be adapted to the needs and complexity of your warehouse, integrated gradually and interfaced with more complex management software. Although it can be used as a stand-alone management software for manual storage systems, Modula WMS is designed to give its best when used with Modula automated storage systems.

Modula automated storage systems make work easier

Skilled labour accounts for the largest share of personnel that is difficult to find in the logistics and supply chain sector. As already mentioned, this is also due to the fact that working in logistics is currently considered tiring and not particularly attractive.

Modula automated storage systems can solve both problems. Investing in Modula products means making your warehouse not only more efficient from an operational point of view but also simpler and more intuitive in the execution of tasks for non-specialized personnel. What are the technologies and solutions adopted to this end?

  • Modula WMS management software, which, as explained above, used with Modula automated storage systems constitutes an all-in-one automation solution.
  • Visual aids such as the Put to Light, which makes it possible to quickly identify which and how many articles must be picked and placed in the Picking Station containers. Accuracy reaches 99%.
  • Automated storage thanks to the Modula automatic vertical storage systems and Modula automatic horizontal storage systems which, conveniently managed from a PC via the Modula WMS, locate the product and transport it automatically to the picking bay, where the operator can pick it up before placing it in the Picking Cart.
  • Robotic applications, such as AMRs and anthropomorphic robots, which can be seamlessly integrated in the Modula automated storage system for moving and handling heavy materials and used in high-density or large warehouses.

With Modula’s automatic storage systems, logistics workers can be autonomous from day one, thus feeling that their job is of greater value and less stressful as the most tiring and monotonous tasks are eliminated. In fact, according to the Edelman Report, 81% of employees consider it important to improve their skills, and a company that offers the opportunity to do so has lower levels of employee turnover and greater employee satisfaction and loyalty.

Space optimization thanks to Modula automatic vertical storage systems

With the growth of e-commerce, warehouse logistics operators need more and more storage space. More space means that more manpower is needed but also that warehouse operators have to cover several kilometres per day to pick items from the shelves, an activity that is also time-consuming.

Modula automatic vertical storage systems make it possible to:

  1. Gain space, as they develop vertically, thus making the most of the storage area.
    The configuration of Modula Lift, which can reach up to 16 m in height, can be customized according to the needs of the warehouse in which it is installed. Inside, the trays containing the items, which are stored following dynamic loading height management principles to optimise empty spaces, are moved by a lift and transported to the picking bay. This means that the operator has to move much less, since using space vertically saves up to 90% of the footprint.
  2. Save time, thanks to the goods-to-man logic and integration with picking solutions
    that allow the operators to prepare the items for shipment without wasting time. The Copilot console can save additional time, allowing the operators to walk even less, as it can be moved along the bay and thus always be at hand for task confirmation.
  3. Improve process efficiency by automating the most repetitive and time-consuming tasks.
    A routine task performed manually can lead to stress, fatigue and a higher error rate, whereas when it is automated the operator can focus on more strategic and management-related tasks.
    The companies that choose a Modula automated vertical storage system need fewer personnel, can count on more satisfied operators, and in addition save costs thanks to the optimization of storage space.

5 ways in which Modula automated storage systems make up for labour shortages

In conclusion, we can say that a Modula automated storage system compensates for the shortage of skilled labour in the following ways:

  1. No specialized personnel are needed. Thanks to the simple and intuitive colour graphic interface of Modula WMS, even unskilled workers can immediately use the Modula storage systems autonomously.
  2. Operators working with a Modula automatic storage system are faster, less stressed by routine operations and make fewer mistakes, thanks to picking solutions, automated storage and the integration of AMRs. This results in more efficient warehouse logistics with less demand for labour, because the risk of reverse logistics is also reduced.
  3. Turnover is reduced due to lower health and safety risks and the automation of strenuous tasks.
  4. More picking cycles can be performed by the same number of operators.
  5. The perceived value of work in the logistics and supply chain sector increases, with greater employee satisfaction.

If your company is experiencing the problem of labour shortages, Modula’s automatic storage systems can be the solution you are looking for.

Article source modula.eu


Products that might interest you:
MODULA Automated Storage Systems

Storage optimization specialists

Good warehouse management is based on multiple factors, but the most important by far is efficiency. Without a simplified and lean organization and production process, warehouse operations are affected and so are costs, personnel, and company performance.

In this article we will explain the critical factors involved in making a warehouse efficient, starting from the optimization of space through improvements in picking accuracy, productivity and even personnel satisfaction.

1) Optimize warehouse space

It is not the size of the warehouse that matters, but how space and resources are used.
To optimize space and therefore increase storage capacity, start with these 4 steps:

  1. Identify the space that is not used in full.
  2. Store items according to their size.
  3. Reduce the width of the aisles between shelving racks.
  4. Remove obsolete inventory.

With a strategic layout, you can avoid cramped spaces, bottlenecks, and inefficient storage.

Modula automatic vertical storage systems can help in this: fully automated vertical storage systems that have a limited footprint because they use the available space up to the ceiling.

Here’s how vertical storage systems can optimize warehouse space:

  • They are designed to optimize the space between one tray and the next, thus maximizing overall storage space.
  • Trays are designed to accommodate heavy loads with no need for hazardous physical work.
  • Trays can be organized by item type/size. Their configuration is not fixed and can be adapted to different sizes and quantities.
  • Vertical storage systems have different types of bays which meet various operational and space needs. Internal bays are best for applications with limited space, while external bays can be useful when integrated with anthropomorphic robots or lift devices.

The best part? Modula storage systems can reduce your footprint by up to 90%. The height can be changed and adjusted, by adding or removing modules, thanks to the modular design of the machines. Should they need to be moved elsewhere, even to another location, Modula storage systems can be quickly adapted to the new height requirements.

2) Improve the accuracy of warehouse operations

Accuracy is paramount in all operations, but some of them really require special attention because if done hastily they can lead to very serious consequences, even the loss of turnover.

One example certainly involves inventory, which if not managed correctly can lead to production and shipping delays, misplaced items, prolonged downtime and, ultimately, economic losses. If your theoretical inventory does not match your physical inventory, backorders could increase and production could be halted to the detriment of the company’s reputation.

Here are some tips to improve accuracy in warehouse operations:

  • Implement a warehouse inventory management system that enables you to work quickly and easily but at the same time accurately.
  • Integrate robots and other automated storage systems (for example Autonomous Mobile Robots, also called AMR).
  • Establish standard picking routes.
  • Train employees to apply thorough inventory control procedures.
  • Investigate and determine the factors that lead to an out-of-stock situation.
  • Automate the reporting process.
  • Use wireless RFIDs.

3) Increase personnel productivity

Personnel productivity plays a key role in business profitability. That is why it is essential to modernize methods and procedures as well as to improve both processes and working environments.

Warehouse automation can eliminate repetitive tasks by giving personnel the opportunity to focus on more “useful” tasks.

How to improve personnel productivity in a warehouse? Here are 4 simple tips:

  • Invest in high-quality training.
  • Provide the workforce with financial incentives.
  • Provide the tools and equipment needed.
  • Ask for ongoing feedback from personnel and consequently implement changes as needed.

Modula automated storage systems are the right solution to dramatically increase productivity and provide a more efficient work environment.

Applying the “goods to person” method, vertical and horizontal automatic storage systems deliver the items directly to the operator, more precisely to a fixed location where all picking operations take place.

Thanks to the visual picking aids, the operator quickly understands which and how many items to pick. This eliminates human error, improving accuracy up to 99%.

4) Personnel satisfaction and safety

According to Eurostatdata, in 2020 2.4% of workers in Europe reported at least one accident at work in the previous 12 months.

Whether it’s a fall, being hit by an object, or being trapped in equipment, they are all potential injuries that could have serious consequences. Physical safety plays a key role in efficient warehouse management.

What to do then? In addition to the classic recommendations such as employing only certified and competent workers, carrying out periodic maintenance of machinery, providing appropriate personal protective equipment (PPE), and organizing periodic training and safety courses, one of the most important aspects also concerns the type of solutions chosen for the warehouse. For example, vertical and horizontal automatic storage systems are designed to reduce unnecessary walking, bending, and stretching that characterize the work of operators in warehouses based on traditional racking solutions. In fact, all picking operations can be performed from a fixed position and this greatly reduces the risk of injury, offering personnel maximum safety even in rather demanding work environments.

In addition, dissatisfaction at work is another factor that must never be underestimated as it causes not only low morale, but also loss of motivation, lack of interest, frustration, low productivity, absences, and increased job rotation. Worker satisfaction is one of the keys to success for an efficient warehouse. This is all the more true when we consider the current labor shortage.

How can a satisfactory work environment be ensured though? Definitely, by simplifying the boring aspects of operations, eliminating some of the monotonous activities that lack real added value, reducing confusion and thus stress levels.

Satisfied personnel are those in safe work environments. A happy worker is a more productive worker.

5) Save on inventory costs

It is well known that managing a warehouse requires considerable resources (storage, utilities, rent, labor, equipment, etc.). For this reason, to achieve efficiency in your warehouse you need to find a way to reduce costs without affecting the quality of the service offered.

Cutting costs without compromising on quality or productivity seems like an unattainable dream for most companies.

Whether you are looking for immediate or long-term solutions, here are some ways to reduce inventory costs:

  1. Ensure that all available space is optimized by reorganizing the warehouse.
  2. Invest in state-of-the-art automation and/or equipment.
  3. Give the highest priority to the scheduled maintenance of the equipment to prevent accidents.
  4. Use energy-saving lighting such as LEDs.
  5. Cultivate employee loyalty rather than trying to recruit new ones who need training.

The last point to add to the list is to use automation which, although initially it may seem an additional cost, actually enables cost optimization in the long run. There are also various solutions to automate a warehouse: the Modula automatic storage systems that we have already mentioned have a relatively low repayment period: from 6 to 18 months.

Article source modula.eu


Products that might interest you:
MODULA Automated Storage Systems

Storage optimization specialists

Automation is a field that’s constantly changing and evolving. Fast-paced innovation is underway in the processes, working tools and technologies that enable systems to operate automatically. The trends that we can expect for 2022 will pave the way to greater simplification, agility, and efficiency.

By bringing production and logistics systems to an extended standstill, the COVID-19 pandemic underlined the extent to which automation can bolster supply chain resilience, even in industries in which its use was inconceivable until a few years ago. This, together with the labour shortages affecting entire industries, showed that automation is the best way to overcome fluctuations in global supply chains.

The rise of e-commerce seems to be unstoppable. It continues to experience double-digit growth and is increasingly demanding the development of software, services and products that can cater to changing needs in an agile, simple way.

Let’s take a look at the five main trends and objectives for automation and Industry 4.0 in 2022.

1) The spread of digital twins

Digital twins are among the most fascinating forms of automation, and they are set to significantly disrupt business processes. In an IDC survey, 70% of respondents said that they were considering adopting them in the near future.

Rather than a type of technology, they take the form of a collection of software solutions that aim to combine the physical and the digital world. Digital twins are virtual models of products or processes that are created – using technologies such as augmented reality, machine learning and the IoT – for use in simulations in order to:

  • Assess new application scenarios and optimize processes.
  • Make changes and fine-tune products.
  • Predict and resolve maintenance issues in machinery (with 30% lower maintenance costs, 75% fewer technical defects and 45% less downtime according to CADFEM).

Virtual simulations and copies will allow companies to decide whether or not to introduce new processes or buy products and machinery, thus preventing waste and optimizing the use of resources. In addition, digital twins can be connected to the sensors on machinery for predictive maintenance purposes. Operations can be monitored almost in real time and potential faults and failures can be reported before they occur.

2) Cloud-native applications

On the cloud scene, the most widely used applications in 2022 will be native ones. That means software and applications that are specially developed to operate in the cloud (hence the name “cloud-native”) and satisfy the huge demand for speed, scalability, and reliability from companies of all sizes.

The key, distinctive features of cloud-native applications are microservices and container technology. Microservices are individual, independent services that perform specific functions but are designed to communicate with each other through APIs. Therefore, microservices can be combined with each other in containers – together with everything required for them to be used – and they can also be integrated in other applications. End users can access a number of services through the same interface.

Another of their distinctive features is that user feedback can be promptly integrated, which encourages regular releases of new solutions.

One of the advantages of cloud native solutions is that they can be built freely, combining components to suit the technological and infrastructural needs of each company. This means that they are faster and more flexible and agile to introduce compared to specially coded solutions.

3) Low-code platforms

Low-code automation platforms are designed to enable users without technical skills to develop applications. They allow staff who are responsible for organizing work to automate processes by using graphic interfaces instead of complex programming languages. All of this makes things simpler for companies and frees up time and resources that can be devoted to the development of business strategies.

In addition, low-code automation platforms are easy to integrate with other applications – including third-party ones – and they can be introduced more quickly because they do not require specific technical know-how. As a result, they are considered to be “democratic automation applications” and, according to Gartner, by 2024 they will be responsible for 65% of all application development activity.

This means that in the future managing the automation of routine operations will be more and more simple, intuitive, and accessible, so companies will be able to invest in upskilling employees.

4) Moving goods with drones and robots

The push for robots and drones to be used for moving goods will be given additional momentum by constant growth in e-commerce and customers who want increasingly customized products and faster, more convenient, and more practical deliveries.

Drones and robots can be used to move goods automatically through the air and on the ground from one area of a logistics plant to another. Together with automatic storage systems, they can be used to set up dark warehouses: fully automated logistics solutions that enable companies to cut costs and eliminate human error thanks to automatic operating cycles.

The latest generation of drones and robots are more and more simple to introduce and manage thanks to the low-code software platforms mentioned above, with which they can be easily integrated.

5) AI and blockchains

Modern working environments provide access to more and more data, also thanks to the ongoing adoption of new technology. When it comes to logistics and supply chains, automatic storage systems, robots, drones and increasingly accessible software have made it easier to get hold of new data for use in business development.

Artificial Intelligence can be used to analyse the data collected by automatic processes, so that informed, data-driven decisions can be made, leading to optimization of the entire supply chain and making the most of the logistics process.

Blockchains – which can be used to securely manage and update records of data and information in networks– can also improve the traceability and transparency of the entire production and supply chain, actually using the vast amounts of data available as a guarantee. Blockchains can help companies to improve their services and the efficiency of supply chains because it is possible to monitor and access information about goods in real time.

Automation in 2022: simplification and agility

The road that has been mapped out in 2022 by innovations in automation will lead to greater simplicity for users – in terms not only of services and software, but also of products – and greater agility.

In recent years, there has been a rapid increase in the adoption of automation systems in all fields that are connected to e-commerce, with logistics leading the way. The warehouses of the future will be increasingly automated and data driven, while supply chains will be more and more resilient and capable of withstanding market fluctuations.


Products that might interest you:
MODULA Automated Storage Systems

Storage optimization specialists

It is plain to see that global supply chains are going through some tough times and the COVID-19 pandemic has made things even worse. The main reasons for the difficulties are as follows:

  • shortages of raw materials
  • labour shortages
  • increased demand.

In this post, we will focus in particular on the labour shortages in supply chains and logistics, the reasons behind them, the problems that they cause and how they can be resolved.

What does it mean to work in logistics and supply chains today?

One of the reasons behind the labour shortage in supply chains and logistics is the mistaken belief that all of the work is of a tiring, physical nature and thus unappealing. This notion is far removed from the actual state of affairs in logistics 4.0: more and more logistics and supply chain companies are adopting cutting-edge software and technological systems to boost the efficiency of their operations, improve the working conditions of their staff and protect their health and safety. For example, they use more ergonomic systems that help to reduce the risk of accidents.

It is also one of the fields in which the impact of activities all along the production chain is being reassessed in a process that revolves around sustainability of all kinds, including on the environmental front. It is hard to find qualified staff to work in logistics today because of the difference between the workforce’s perception of the industry and the actual situation in terms of the working conditions and skills required.

Ways for supply chains to make up for the decrease in the labour supply

In 2021, filling vacancies for key positions in supply chains proved to be particularly difficult: 36% of the employers interviewed for the Summer 2021 Labour Market Outlook report stated that they had trouble finding staff, compared to 26% in the previous year.

Companies and supply managers can deal with labour shortages in a variety of ways:

Improving communication

Given that people clearly have mistaken views about the working conditions in supply chains, companies should change the way they communicate with the labour market in order to find qualified staff in strategic sectors such as transport and logistics. This is even more essential because the majority of the potential candidates are Millennials and members of Generation Z who have mistaken beliefs and a lack of trust in the industry.

Investing in automation and technology

Supply chain decisions can be data-driven, goods can be processed and handled using automation and mobile robots, and wearable devices can make work easier for staff. All of this helps to make the industry more attractive and means that jobs today have more in common with clerical and management roles than manufacturing jobs. Candidates are required to have an increasingly broad range of both physical and technical skills. If the supply chain is automated and run with technological support, the field will be more attractive.

Increasing storage spaces

COVID-19 has highlighted the limitations of just-in-time logistics. It is a production model that can be put under great strain by fluctuations in the market, and labour shortages further restrict its capacity to respond to surges in demand. Increasing just-in-case stocks gives greater resilience and makes it possible to respond to peaks in demand promptly even if there are labour shortages, but only if the warehouse and logistics systems have certain characteristics.

Logistics 4.0 as a solution to the supply chain crisis

While logistics and increasing stock can be a new frontier in improving the resilience of modern supply chains, they do lead to two potential issues:

  • overburdening staff
  • a lack of floor space.

Once again, the solution can be provided by technology.

Autonomous mobile robots

Autonomous mobile robots and wearable devices

Artificial Intelligence companies have developed high-performance autonomous mobile robots to help logistics staff to handle, load and unload goods.

Supply chain and logistics companies are well aware of this and use of these solutions is soaring: Brain Corp reported 226% growth in the floor area covered by its AMRs between April and October 2021.

This underlines how receptive the industry is to technological innovation and the indispensable role played by this innovation in meeting the requirements of logistics today. An autonomous mobile robot has the capability to work non-stop at a pace that would not be humanly possible, thus making it easier to deal with peaks in demand.

Meanwhile, members of staff are relieved of their more physically demanding duties and can focus on the supervision and planning side of things. In addition, wearable devices can help them to notice any difficulties in the warehouse quickly and take the necessary action.

Autonomous storage systems

Increasing stock to boost resilience inevitably means that more storage space is needed. As well as finding warehouses with more floor area, another way to increase capacity is to optimize the space used.

In the latter case, the obvious answer lies in vertical storage systems, which stretch upwards and make the most of the space available in all directions. Automatic storage systems such as the Modula Lift are based on the goods-to-person approach. A central lift system moves trays from the storage sections to the picking bays, where the materials are delivered to the staff in ergonomic positions.

Another advantage of autonomous storage systems lies in that they can be fully integrated with technological warehouse management systems, increasing the speed and overall efficiency of warehouse operations without leading to excessive stress or physical workloads for staff. Modern picking solutions make work easier for pickers and automatic storage systems the number one choice among companies looking for cutting-edge ways to improve performance and working conditions.

Article source modula.eu


Products that might interest you:
MODULA Automated Storage Systems

Storage optimization specialists

The uptick in eCommerce demand and the need to store more items on-shore, thanks largely to the recent global pandemic, has made it more difficult for warehouses to meet consumer demands and fulfill operations.

To overcome these challenges, many businesses are looking for automation.

In this article, we’ll share everything you need to know about warehouse automation, from different types to the many benefits you can reap by integrating these solutions into your warehouse operations.

What Is Warehouse Automation?

Warehouse automation uses robotics and automated storage and retrieval systems to automate the handling of inventory into, within, and out of the warehouse.

Automation helps businesses minimize labor-intensive duties such as manual data entry and repetitive physical work while increasing employee safety and operational productivity.

Warehouse automation is used to streamline different warehouse processes such as receiving, returns, picking, sorting and shipping.

From taking advantage of your existing warehouse space to increasing productivity, here are six key benefits you can look forward to when implementing automation.

AMRs transport goods, reduce walking time and increase employee safety.
AMRs are intelligent robots that use sensors and artificial intelligence to travel the warehouse without human supervision

1. Optimized Warehouse Space

According to a recent study, global retail eCommerce sales are expected to reach $7.4 trillion by 2025.

While moving into a bigger warehouse to store a larger inventory may be an option for some companies, investing in smart systems (think vertical lift modules) can free up as much as 90% of your warehouse space.

2. Increased Employee Safety

According to the National Safety Council, work injuries that required medical care cost an average of $42,000 per employee in 2019. Unsurprisingly, common warehouse accidents such as falls, trips and slips were ranked second for top workplace accidents.

Automated solutions help prevent employees from experiencing workplace injuries in several ways: they handle the heavy lifting, bring items directly to employees, and perform other tasks that may be hazardous for employees.

3. Better Inventory Control and Visibility

Manual inventory management is time consuming and prone to human error.

The solution to simplified and accurate counting? Warehouse automation.

Automated systems continuously update your POS software, which results in accurate inventory data. In addition to accurate counts, a warehouse management system provides inventory visibility down to a specific tray or item.

4. Increased Warehouse Throughput

A recent survey found that more than 40% of consumers in the U.S. expected their online packages to be delivered within two to three days, while 27% said that they hoped to receive their deliveries within the same day.

When you increase your warehouse throughput, you can increase customer retention by delivering accurate purchase items within their expected delivery time.

Our Modula horizontal carousels, for example, offer increased picking rates of up to 550 lines per hour, along with a picking accuracy of up to 99%.

Modula Horizontal Carousel
Modula’s horizontal carousels provide reliability and fast picking rates in low ceiling environments

5. Streamlined Picking Process

A recent report found that 25% of customers return between 5% and 15% of items they purchased online because they received the wrong item.

Mispicks are costly errors that occur when an employee picks the wrong item or quantity of items, fails to pack an item or mislabels an order.

With just a few taps on the screen, Modula’s horizontal carousels and vertical lift modules deliver the correct items to employees.

Wrapping Up on Warehouse Automation

Warehouse automation provides a streamlined solution for warehouses to fulfill orders and meet consumer demands, despite the challenges the warehouse industry faces.

The most common types of automated solutions include automated storage and retrieval systems, autonomous mobile robots, and goods-to-person solutions.

The key benefits you can expect when implementing automation in your warehouse include:

  • Optimized warehouse space
  • Increased employee safety
  • Better inventory control and visibility
  • Increased warehouse throughput
  • Streamlined picking process

A batch picking in a warehouse using a picking station and Modula VLMs

At Modula, our solutions range from horizontal and vertical carousels to order picking solutions and more. Further, streamline your warehouse operations and get the full experience when you combine your sorting and retrieval systems, warehouse management system, and picking aids such as the Put-to-Light system.

Article source modula.us


Products that might interest you:
MODULA Automated Storage Systems

Storage optimization specialists

Warehouse picking is one of the most important phases in order preparation: it involves picking the specific items of an order and then preparing them for shipment.

It is a process that requires both high-tech equipment and optimal organization of the manual work to ensure accuracy in the preparation and fulfillment of orders. Indeed, any inefficiency in this phase translates into a slowdown of the entire order preparation process.

For this reason, technologies and picking solutions aimed at increasing warehouse productivity have developed over time. The choice of the order preparation method is, in fact, strategic both for proper warehouse management and for company performance.

Among the systems developed for the picking phase, batch picking is one of the most efficient. Let’s take a look at this picking strategy, exploring the technologies and sectors in which this method is more successful.

MODULA batch picking

What is batch picking and how does it work?

Batch picking is one of the person-to-goods methods by which items are picked for order preparation. In this method, the operator picks multiple items of the same type at the same time (batches) and then sorts them into the different orders.

Once finished, the batch of orders moves to another storage area where additional items will be picked, until the orders are complete.

The goal of batch picking is to reduce the number of trips personnel must make to the picking areas, thus increasing operational efficiency.

What are the main characteristics of batch picking?

The batch picking method can be implemented with different levels of automation, depending on the type of warehouse. In general, the more the warehouse is managed automatically, the more efficient batch picking will be, with a margin of error close to zero.

Batch picking can generally be divided into 4 phases:

  • A picking list is generated, that is, a document with the items to be shipped, the quantities for each item, and their storage position in the warehouse. The picking list may be on paper, in smaller warehouses, but more often this operation is managed digitally.
  • Orders are grouped – automatically and in the most efficient way if there is an order management system or WMS – so as to include the same items for each batch of orders.
  • The picking lists, ordered according to the batch picking route suggested by the WMS, are assigned to the picking personnel. If the warehouse does not have an automatic management system, it is also necessary to determine the recommended route.
  • The warehouse operator, following the picking list, picks the items according to the batch picking route, until completing the batch of orders assigned to them, and at that point, the order is passed to the personnel in charge of packing.

Thus, adopting automatic warehouse management systems and implementing cutting-edge technologies exponentially enhances the efficiency of batch picking.


A batch picking in a warehouse using a picking station and Modula VLMs

What technologies are needed to implement the batch picking method?

To efficiently implement batch picking, ad hoc software can be used to reduce the distances to be covered and the repetition of movements. Warehouse management systems (WMS) are modular solutions for managing flows in warehouses which, by interfacing with other devices, can also simplify batch picking functions.

Modula picking aids for order preparation are:

  • Put to Light – The system with a display that guides the operator to the positions in which to put the items of each order. For each item, the display visually indicates the container and quantity of each SKU to be inserted. Thanks to the WMS, the Put to Light system can also be implemented for the batch picking method.
  • Picking Station – Steel structures with shelves for containers, which can be integrated in traditional warehouses with manual transport or in modern warehouses with automated transport. These are the structures on which the Put to Light device works best.
  • Picking Carts – Unlike fixed Picking Stations, Picking Carts are maneuverable carts with pivoting wheels. They are equipped with shelves for containers and Put to Light displays for the easy identification of the container in which the picked item must be placed. Picking Carts for batch picking may be used in warehouses with traditional shelving as well as in automatic vertical storage systems.

Modula picking

When it is advantageous to implement the batch picking method?

The batch picking method is particularly effective and optimized when:

  • The items to be picked are homogeneous and small in size – In this way the operator can easily prepare batches of orders by placing them in the picking cart.
  • The company has many orders to process – Order preparation and retrieval times for the items involved are reduced, which results in less warehouse congestion.
  • Orders have just a few and homogeneous SKUs – In this way the picking and sorting process can be carried out together and simultaneously, with a further reduction of picking errors.

The advantages of batch picking in order preparation are therefore:

  1. Reduction of the number of trips
  2. Reduction of labor and related costs
  3. Reduction of fatigue
  4. Increased productivity

In addition, with the Mobile Picking APP, compatible with Android systems, it is possible to communicate directly with the Modula WMS which guides the picker, thus increasing efficiency.

Which sectors use batch picking the most?

Batch picking, as seen above, offers undisputable advantages for the management of warehouses where the number of items is not excessively large and the orders are rather homogeneous. This makes it the preferred picking strategy for e-commerce – regardless of the sector – where order preparation speed and accuracy must be at the highest levels.

Article source modula.eu


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Storage optimization specialists

The world of logistics, warehouse management, and order fulfillment has undergone numerous changes in recent years, with an ever-increasing demand for efficiency and productivity, to the point that today customers can count on delivery times within two hours from the order. Staying up to date on new procedures and adopting the latest technology becomes essential for companies with the drive to remain competitive and adapt to new market needs.

When it comes to increasing efficiency and productivity in warehouse logistics, automation cannot be ignored. Warehouse robotics is certainly a competitive lever and among the various solutions available Autonomous Mobile Robots (AMR) are proving to be one of the most revolutionary and innovative.

Automated Mobile Robot

What are Autonomous Mobile Robots (AMR)?

An Autonomous Mobile Robot is any robot capable of moving in the environment in which it is located without the need to be supervised by an operator or the need for a fixed and predetermined path. This means that it is a very sophisticated robot, capable of understanding the environment around it thanks to the presence of sensors that allow it to:

  • Carry out its tasks in the most efficient way and taking the shortest possible route
  • Avoid collisions with fixed obstacles (such as fixed structures, shelves, workstations, etc.)
  • Avoid collisions with moving obstacles (such as operators, forklifts, etc.).

Other technologies used in warehouse management also perform similar functions (AGVs, for example), but only AMRs offer the kind of flexibility that enable them to always choose the best and safest route when carrying out their tasks. In addition to this, they are able to collaborate with operators during picking and sorting operations.

Integration with warehouse control systems means that Autonomous Mobile Robots can create their own routes and make processes and workflows more efficient and productive, as they perform tasks such as transport, picking, delivery and placement of goods, even in less healthy or hazardous environments, while allowing operators to carry out tasks with greater added value and in safer conditions.

Now let’s see what types of Autonomous Mobile Robots exist and how they can be used in warehouses.

Autonomous Mobile Robots

Types of Autonomous Mobile Robots based on their intended use

Since they were first used by NASA for space exploration, AMRs have become a real strategic asset for optimizing the entire supply chain.

For this reason, they are usually distinguished by the tasks performed within the warehouse rather than by model. There are 3 main categories of autonomous automatic robots:

1. AMRs designed to transport and sort goods within a facility or warehouse

Transporting, sorting, and handling goods within a facility are the first operations to be automated where possible. In fact, even if these tasks provide no added value, they require time and staff resources.

Automating the transport of goods frees up personnel who can take on more critical tasks with no need to move from their workstation. There are of course different AMR solutions for handling goods, such as:

  • Roller conveyors
  • Tiltable trays
  • Cross belt sorters.

Each system helps improve warehouse efficiency by handling goods in different weights and shapes, ranging from heavy pallets to small objects.

2. AMRs designed to support picking processes

Order preparation can be one of the most expensive activities in warehouse management, not so much because it requires qualified personnel but because of the time it takes personnel to move from one place to another to pick goods. AMRs make it possible to significantly reduce travel times from one area of the warehouse to another for picking the various items.

The operating approaches usually applied to picking are:

  • Area picking: Each operator in charge of the picking process is assigned an area of the warehouse where the goods are stored. AMRs, which are equipped with an interface showing all the information on the order, move through the various areas of the warehouse with a container where the operators place the items indicated on the interface. Once all the items included in the order have been picked from the various areas of the warehouse, the robot moves to the packaging, consolidation or shipping area. This picking method enables the distribution center to simultaneously manage and complete a large number of orders and is, therefore, an optimal solution for e-commerce.
  • Goods-to-person picking: In area picking, in any case, a certain amount of time is wasted, given that the operator has to search for the item stored on the shelves. With G2P logic (that is, goods to person), the aforementioned waste of time is further reduced. In fact, the operator is assigned a picking station to prepare the order, while the AMRs move through the shelves and find exactly the one where the required item is stored. The shelf with the related item is brought to the operator who simply puts it in the order being prepared.

Picking can also be 100% automated by integrating AMRs with tray-based automatic storage systems. Autonomous mobile robots can in fact communicate directly with the storage system and request the needed product along their route. In this way, when the AMR reaches the picking/placing bay the product is ready for picking, while the barcode near the bay is read to confirm the operation.

3. AMRs for inventory activities

Managing a large distribution center or a warehouse involves another important process that requires significant time and resources: inventory. Knowing the quantities of items stored, placed, picked and processed in real time is critical to minimize errors and bottlenecks or shutdowns.

Also in this case, AMRs are an excellent ally as they can replace the staff who usually carry out time consuming and error-prone activities such as the transport and handling of goods. In fact, when integrated with the warehouse management system, AMRs enable the automation of the inventory process, drastically reducing the time required for this activity and optimizing productivity and accuracy in order fulfillment.

Moreover, inventory activities can be often managed by synergically combining specific automated solutions, for example RFID technology (and RFID gates and portals for goods identification) and AMRs for handling goods (even full pallets or shelves).

Autonomous mobile robots

The advantages of autonomous mobile robots for distribution centers and warehouses

Within a distribution center or a warehouse, the efficiency of the picking phase (for order preparation) is one of the most important and useful elements for assessing the productivity of the entire logistics process. AMRs can significantly speed up this phase, which means more orders fulfilled per hour with fewer personnel.

An AMR can double the productivity of a picking operator.

We can therefore summarize the advantages provided by the use of Autonomous Mobile Robots in warehouses as follows:

  • Reduction in personnel costs
  • Increase in the productivity of workers
  • More orders fulfilled
  • Fewer errors in order preparation and therefore fewer returns
  • Increase in worker safety, given that AMRs carry out the most physically demanding tasks and access the most hazardous or unhealthy areas of the warehouse.

Article source modula.eu


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MODULA Automated Storage Systems

Storage optimization specialists

An effective and efficient supply chain requires accurate planning ahead of time. Since this is a highly complex process involving many resources that must be organized, any change can result in criticalities affecting the performance of the entire distribution chain.

Global changes, such as the ones we experienced in recent times, certainly affect the management of a supply chain. This period, like others in the past, has changed the habits of end consumers and companies are required to adapt to the new demand quickly enough, in order not to lose the trust of customers as well as personnel and partners.

Faced with radical changes, how can companies not only survive but even drive change and create opportunities for improvement?

The critical factor for success is the company’s ability to move from an exclusively lean approach to an agile approach: redesigning the supply chain with new methods able to minimize risks while at the same time taking advantage of all the innovative resources that the logistics industry has been proposing in recent years.

Key concept: redesign the supply chain focusing on agility and resilience.

The agile approach: How to manage risk with greater speed and flexibility

Let’s start with the assumption that the company already has well-defined processes and that it is willing to re-configure them to meet the needs arising from problems detected in the field (internal factors) or from economic and/or social shocks (external factors).

One of the first steps to be taken is transparent communication with all the players in the chain, a fundamental prerequisite for the strategic planning of all production. Precisely because the supply chain is made up of different players, in order to face sudden changes, it is essential to communicate quickly with all of them to reprogram the processes in the shortest possible time. This is possible only if at the base there is clear sharing of information along the entire supply chain.

Second, the approach must shift from a classic approach characterized by maximum efficiency to a modern approach based on flexibility. This can be done by taking advantage of the pillars of Industry 4.0 such as the Internet of Things (IoT) and Big Data.

Thanks to the application of the Internet of Things, a company can easily trace products and processes in real-time all along the supply and distribution chain, as well as manage sale conditions depending on raw material prices. Connecting machines and industrial plants with the Internet of Things is a challenge that will completely change the entire production process in the medium term. A hypothetical fully automated company based on the IoT-approach (therefore equipped, for example, with transfer machines, intelligent robots, automatic vertical storage systems) and operating according to the logistic approach of a DIO (Direct Input/Output) system, will be able to manage all critical areas in real time: offices, production areas, automatic storage systems and public areas.

In such a scenario vertical storage technologies are paramount: they are in fact able to efficiently manage warehouse handling and logistics by means of software applications. All this leads to a significant improvement in the supply chain if all the partners and suppliers who are part of it are involved in an organic and integrated way.

Big Data, on the other hand, helps to identify, locate and intercept increasing or decreasing trends in demand. Only the interconnection and sharing of data facilitates access to information and resources for the benefit of the entire business ecosystem, contrary to the principle of possessing information as a source of power.

A return to proactive inventory for resilient logistics

The efficient management of inventory and the supply of goods helps to reduce costs, improve customer satisfaction and increase productivity of any industrial business.

The really important thing is to transform the information obtained into a rapid and effective response aimed at improving intralogistics. Making reliable forecasts is difficult even for the best managed companies. The concrete alternative is to allocate a minimum of stock in order to cope with forecast uncertainty even in the event of a sudden interruption of critical supplies.

Logistics

What are the steps to design a resilient supply chain?

  1. Understand and analyze the company’s intralogistics
  2. Map processes with suppliers and customers
  3. Identify risks
  4. Manage risk
  5. Take an agile and not just a lean approach
  6. Automate
What to do concretely to change approach?

First of all, shift from a conflictual relationship to a collaborative relationship with customers and suppliers. Visibility and transparency are critical: never lie about the availability of a given product or confirm shipments that can never actually be delivered in time just to prevent the customer from changing supplier.

Above all, it is important to adopt 4.0 automation systems capable of protecting the people who work for us and buy from us, as well as the environment in which we live and work.

Automation plays and will increasingly play a strategic role in emergency situations but also in the management of everyday tasks.

For example, in the case of automatic vertical storage systems, the operator can stay in a fixed position and pick the requested items with no need to move or interact with other colleagues. Social distancing is guaranteed since the minimum width of a tray is 1.3 meters.

The advantages of automation: automatic vertical storage systems

Modula-Vertical-Lift-Module

It is no coincidence that automation has kept growing over the last 10 years. Specifically, thanks to automation, in warehouses we have shifted from the “person to goods” to the “goods to person” approach, which offers significant advantages. There are many automated solutions available for automatic storage and picking, but vertical storage systems certainly outpace other solutions with their remarkable flexibility.

Their most obvious advantages are:

  • Higher productivity and efficiency
  • Fewer picking errors
  • Lower production costs

By integrating picking assistance systems in automatic storage solutions, operators are guided in the selection of the items to pick, considerably reducing the margin of error and order preparation times. The double bay also improves efficiency: while one tray is in the bay for a picking operation, the lift prepares the next tray for the successive one. This ensures an increase in productivity and ever greater efficiency within the warehouse.

Automated picking, the perfect ally for agile logistics

Transparency and communication must help supply chain managers to optimize all logistics processes, especially warehouse management and all related activities.

Picking, in particular, is the heart of the warehouse and for this reason is one of the priorities when it comes to optimizing warehouse activities. In fact, picking is the process during which individual items are collected from shelves, pallets or more simply from material storage areas.

Anthropomorphic robots, autonomous mobile robots and cobots: all these systems are able to improve and automate the picking phase. However, the greatest advantages are obtained when they are installed in combination, for example with an automatic vertical storage system, because they make the picking and placing process very agile.

Automatic picking technology operates at speeds and efficiency rates that manual picking can never match. While it is true that there are ways to improve manual picking, automatic systems are more efficient, especially in situations with many different items where it is necessary to operate quickly and without mistakes (especially when orders are concentrated in specific time frames).

Article source modula.eu


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Storage optimization specialists

Just In Time is a production management methodology which consists of producing only those quantities of each item requested in a short period of time. If adopting this approach, stocks no longer exist or consist of only small reserves for ensuring supply between one production centre and the next. Just In Time has rightly been defined as a philosophy which involves a company’s entire organisation and has consequences such as the drastic reduction in stocks. A categorical imperative is therefore to eliminate “superfluous” stocks, highlighting and eliminating all inefficiencies and dysfunctional aspects.

How do you go from the “philosophy” of Just In Time to the practice?

Let’s start with an observation that may seem obvious, but which constitutes the fundamental basis of this entire methodology: a manufacturing system without stock can be stopped or adjusted.

But how do you manufacture things with zero or minimal stocks? The main routes are as follows:

  • Manufacture only what is required by the market in a very short timeframe and therefore in nearly identical batches.
  • Balance production rates across different production lines.
  • Implement a perfect information transmission system.
  • Provide suitably laid-out production facilities.

Just In Time: a “pull” system

Push vs Pull manufacturing

With a “pull system”, your chances of being able to produce only what is demanded by your clients and therefore reach near-zero stock levels are of course very good.

Manufacturing on the basis of orders received, materials are fed (raw or semi-finished materials) into the production process based on a predetermined production schedule, with particular attention being paid to the needs of the production line using them. The production rate is always determined by the downstream line (production centre) which requests availability of the necessary materials from the upstream line.

But how does this work in practice? This is done by performing the following 4 steps in sequence:

  1. Determine a final assembly schedule;
  2. Smooth out the final assembly schedule;
  3. Develop a master production schedule;
  4. Set detailed production schedules for all production centres.

The final assembly schedule is drawn up a few months in advance, but is adjusted bit-by-bit as the actual production dates approach. At the start this is a plan based on predictions but in the end becomes a plan based mainly on already received client orders and generally has a timeframe which is not too long-term.

Smoothing out the final assembly schedule is intended to balance as far as possible production rates and therefore all production resources. Smoothing out is guided by the market and can be carried out thanks to the ability to produce very small batches.

The master production schedule is nothing more than a daily summary of the quantities to be produced of each item. Detailed production schedules are obtained by exploding the bills of materials contained in the master production schedule.

The critical point in the pull logic is this “smoothing out”. This means that it must be possible and economical to produce single batches because balanced production in short or very short timescales requires a little bit of everything to be produced each day in batches to be assembled into a whole product.

How do you transmit information quickly and efficiently? Using the Kanban system

For a Pull system to operate correctly, you need perfect information transmission: each operation to be performed inside a production facility must be properly documented so it is performed at the right moment and in the correct manner.

One very simple and, at the same time, quick and efficient information transmission method is the so-called Kanban system. This system is based on the circulation of cards between the various production and storage facilities within a factory. The delivery of a card authorises a particular operation to be performed.

kanban system

The Kanban system is activated by the final assembly line which retrieves items from its own incoming storage unit and the cards then move upwards to the storage point for the preceding production centre and so on. In this way, each production centre knows exactly what to produce and at what rate to produce it. This means they will only produce exclusively what the downstream facility can use.

Physical layout of a Pull system

Implementing a Just In Time system requires work to be carried out on a range of different areas in order to improve the efficiency of the production process. One of these concerns the layout of the buildings housing the production equipment.

In order to create a layout suitable for a Pull system, you need to:

  • Organise production into production centres: each of these centres must have incoming and outgoing storage points. Stocks of materials being used in the manufacturing process or part components shall be located exclusively in these areas.
  • There shall be only one resupply point for each material within the factory.
  • The exact routes each material will take through the production centres and related storage points shall be defined and specified.

In a traditional factory, production equipment is generally kept completely separate from the various warehouses used to store raw materials, semi-finished products and finished products.

In a factory using a Pull system, however, warehouses containing raw materials and finished products have practically disappeared, whilst those containing semi-finished products are replaced with small buffer areas containing enough stock to cover consumption of a few hours (or maximum a few days) and which are necessarily located within the production area close to the production lines in question. In this way, the produced materials, or those awaiting production, are visible to production staff who can therefore immediately detect excessive accumulation or depletion of these components and take the necessary immediate action.

In these buffer areas, the automatic vertical warehouse represents the best solution for mixed storage of raw materials, semi-finished products or finished products.

modula

First of all, they allow you to reduce the floor space occupied by stocks of materials by 90% and further reduce buffer areas by concentrating all picking operations in a small space, thereby speeding up and simplifying the work of your operators.

Secondly, they make picking errors practically impossible. In a Pull system, errors represent a significant risk because, if you are using this model, everything must be aligned and work perfectly in order not to create delays or stoppages in the subsequent manufacturing phase.

Having the right piece or the necessary material in the right place at the right time becomes fundamental to the efficiency of the entire production line for which the crucial functioning of the warehouse is pivotal.

Article source modula.eu


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