FEATURE Automated Warehousing
benefi ts by, for example, automating the movement of carts used to transport picked orders or returns. Instead of spending more than half the day walking, workers can park carts in pick-up locations and call robots to retrieve them. Additionally, robotic palletisers/depalletisers limit the need for heavy and awkward lifting by people. While these and other advanced forms of automation handle the repetitive, diffi cult and time-consuming tasks, scarce labour resources can be shifted to higher-value jobs, which in turn can decrease employee disgruntlement.
3. Persistent labour shortage, technical skills gap and training The number of warehouses globally is forecast to rise from some 150,000 in 2020 to 180,000 by 2025, states Interact Analysis. Without added automation, an additional 3.5 million warehouse workers are needed to cover that expansion. In any case, a willing workforce is proving very diffi cult to fi nd, and competition for these resources is high. As a result, warehouse and DC operators will look to expand automation, but this creates another fast-developing problem: the technical skills needed to utilise, maintain and optimise warehouse automation. Operators will actively look to outsource automation-related training, which will make warehouse jobs more attractive and drive higher compensation, thus making the overall market more compelling for job seekers and those looking for career growth.
4. The use of digital twins will accelerate, to help automated warehouse planning Digital twins deliver virtual representations of a physical environment, proving extremely helpful in the warehouse industry. With a digital twin, new automation technology can be tested virtually, without downtime or re- arrangement of physical assets. Automation eff orts can be tested and impacts reviewed. By using digital twins and synthetic data modelling, warehouse operators can close the loop between planning, training and implementation on the fl oor. With this technology, what used to equate to months of automation implementation can now be accomplished in days. In short, warehouse performance can be improved far more quickly and cost eff ectively than before.
5. Human health and safety will become a business case for automation in the warehouse environment Regardless of whether there are health and
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safety issues at a particular warehouse, the overall industry suffers from a health and safety image problem. It’s well documented that concerns in these areas are either keeping workers away from the industry entirely or causing problems with existing employee satisfaction.
Automation can help. Repetitive movement-related injuries and those due to heavy and awkward lifting, as well as worker fatigue, can be greatly mitigated by robotics and automation. Using technology can lead to far fewer work-related injuries, keeping workers in jobs, and mitigating insurance premiums and worker compensation claims for the employer. By prioritising happier, healthier workforce, there will be an uptick in retention and warehouse job appeal.
6. Accelerated dark warehouse research and development Dark warehouses promise to be nearly fully automated and autonomous, operating virtually free from human intervention – aside from planning, maintenance and ongoing optimisation. They will operate 24/7/365 in no light (thus “dark warehouse”) and in any temperature environments, saving energy and lowering costs. They promise to help solve the labour shortage and improve efficiencies. However, full concepts are still at least two years away, with live implementations at least three. Breakthrough technologies in robotics, sensing and control and IT are still needed. But, demand is so strong that it’s beginning to drive more R&D investment to achieve these developments faster. Meanwhile, forward-looking warehouse operators are starting the journey to dark warehouses by not only putting automation piece parts in place as described here, but also tying technologies together via software, such as Warehouse Execution Systems, allowing all the technologies to communicate. As promising as it is, the brave new world of dark warehouses will also contribute to the developing of technical skills. Operators will need to plan for that, as well as determine the types of sectors, environments and industries that are most appropriate for the early adoption of dark warehouses.
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Automation | September 2022 35
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