Warehouse Automation

Warehouse automation is no longer limited to simply replacing human labor with machines. It is a comprehensive process that uses advanced technologies such as automation, information technology, and robotics to create more efficient, precise, and flexible logistics systems. Companies that successfully implement automation solutions have the opportunity not only to increase their competitiveness, but also to improve customer service quality and optimize operational costs.

The article below describes the automation process of a typical warehouse in which products are transported and sorted. The material also includes a presentation of common types of automatic sorting systems that are typically deployed in warehouses.

The rapid growth of companies, particularly in the e-commerce sector, is driving businesses to look for ways to automate their warehouses. They observe that manually performing all warehouse operations leads to numerous problems, mainly related to extended order fulfillment times and an increased risk of losing parcels or products.

Warehouses in which automation has been implemented are characterized by faster operations, shorter delivery times, as well as higher efficiency and accuracy for each completed order. Thanks to automation, such warehouses outperform non-automated facilities and achieve success in a competitive market. Warehouse automation makes it possible to streamline existing procedures and operations, as well as to increase warehouse capacity and throughput. It also improves the working conditions of warehouse employees, as products are transported and sorted automatically, reducing the amount of heavy manual labor.

Before project implementation, it is necessary to develop a final system concept and make decisions about which devices best meet the investor’s needs. At the concept development stage, preparing a visual project proposal plays a key role, as it allows improvements or changes to be introduced in line with requirements. After consultations and the development of the final project version, implementation of the automatic internal transport and product sorting system in the warehouse can begin.

Graphics.1. Project visualisation

Typically, the installation covers several warehouse halls or floors as well as a sorting area. Packaged products, for example in cartons, are automatically transported from all halls to the sorting area, where they are delivered to the appropriate destinations on the sorter. The control system reads the barcode placed on the package and, based on the available data, directs the product to the correct destination.

The system is integrated with a higher-level IT system, WMS/WCS (Warehouse Management System / Warehouse Control System), which allows the PLC (Programmable Logic Controller) to determine the correct destination for each package. The product flow is continuously monitored and fully tracked using optical sensors and cameras.

Graphics 2. Parcel tracking

After defining the system requirements, a Functional Design Specification (FDS) document is prepared, which describes the assumptions and overall concept of the entire system in detail. This document includes:

• a description of the components that will make up the system, including both mechanical elements and control system components,
• a description of the products to be transported by the system, along with information on dimensions, weight, etc.,
• the required system throughput,
• drawings and diagrams of the transport lines,
• system operating scenarios and responses to exceptional situations,
• tasks assigned to system operators,
• a description of safety systems and their operation,
• the project implementation schedule.

Once the document is completed and approved by the investor, the project contractor can proceed with building the system, which consists of mechanical, electrical, and control components.

Graphics 3. On site commissioning

For each transport system implementation, a 3D simulation of the installation should be created and the correctness of the developed software should be verified virtually. Such tests give the investor the opportunity to validate the proposed system and analyze its functionality long before physical installation and commissioning take place. During the FAT (Factory Acceptance Test) meeting, a virtual start-up is performed, in which the PLC controller and the SCADA system (Supervisory Control And Data Acquisition) are connected to a virtual model of the facility and execute real warehouse operations using programmed algorithms.

After the FAT acceptance meeting, work at the site begins. The project execution starts with mechanical assembly and electrical works, including the installation of control cabinets. Next, the control system is commissioned and operational tests are carried out. At the final stage of the project, final acceptance tests are performed and system operators are trained. Depending on the investor’s needs, system integrators may also offer technical support during the first months of system operation.

One of the key components of an automated warehouse is the automatic sorting system, which may consist of one or several sorters. These systems transport orders to specific destinations, such as courier zones, and also operate in the reverse direction by receiving inbound goods and assigning them to appropriate warehouse locations.

There are many reasons why companies decide to automate sorting processes, depending on the nature of the business, the application, or the destination of the goods. To perform such sorting, a series of repetitive and often tedious tasks must be carried out, involving visual inspection and scanning the barcode of each item and then placing it in the correct location. With large volumes of goods, it becomes difficult to ensure sufficient efficiency and continuity of the sorting process. Physical workers are increasingly reluctant to take on such tasks, which is evident in the labor market.

Manual sorting processes are highly susceptible to human error resulting from the repetitive nature of the work. Incorrect routing of goods and delivery to the wrong recipient is very costly for a company, as it involves complaints and returns, as well as re-shipment of the goods.

Graphics 4. Example implementation of an automated sorter

• Higher efficiency and increased throughput – seamless handling of large volumes of goods, reduction of bottlenecks during peak order periods, and an increased number of parcels processed per shift.
• Error reduction and improved customer service quality – product identification is handled by a vision system, ensuring that each parcel is automatically routed to the correct destination. This helps eliminate errors and mistakes that often occur during manual sorting, resulting in higher customer satisfaction.
• Lower operational costs – fewer labor hours required for the same order volume, a reduced number of complaints caused by human errors, and more efficient use of energy and resources thanks to process stability.
• Optimal use of warehouse space – installing a sorter in the warehouse enables efficient use of available space and integrates different warehouse zones into a single, coherent system consisting of the sorter and configurable infeed lines. The sorter itself can also be expanded when needed, for example by adding new destinations.
• Improved safety – reduced manual lifting and less movement across the warehouse for operators. Instead of performing heavy and injury-prone physical work, operators can focus on supervising the sorter and supporting the process when necessary.
• Process flexibility and continuous optimization – automated sorting is a process that can be adapted to changing requirements. The sorter can be customized to different types of operations. The sorting system records data such as cycle times, loads, errors, and downtime, which can later be used for system optimization and performance improvements.

As an experienced control systems integrator, we program, commission, and integrate automatic sorting systems such as roller top sorters, narrow belt sorters, shoe sorters, pop-up sorters, and cross-belt sorters. Control systems for automatic sorters must offer the highest possible accuracy to ensure continuous, high-speed product flow and to prevent sorting errors. We integrate automatic sorters with scanning tunnels that provide up-to-date information on each parcel through communication with the customer’s IT system.

Our role in commissioning sorting systems does not end with start-up. Our engineers transfer their knowledge of the control system to the customer’s technical department and also participate in potential system optimizations, as well as implement improvements under warranty or post-warranty support. Depending on the service agreement, we provide a dedicated engineer who remains available to support the customer in the event of any issues related to the operation of the sorting system.

Graphics 5. Sorting technologies

The implementation of a comprehensive warehouse control system brings numerous benefits, with each project always tailored to the investor’s specific needs. The wide range of industrial automation equipment available on the market makes it possible to automate many warehouse operations. The presented sorting systems can be adapted to the specific requirements and characteristics of a given warehouse. Properly implemented warehouse automation combined with an advanced control system allows warehouse processes to be optimized and improved, which directly translates into increased company competitiveness.

In the field of intralogistics, we have already completed hundreds of projects, gaining extensive experience and expertise. We have been present on the market for over 15 years, and our experience has been built through the execution of numerous projects in Poland and abroad. Among others, we have been involved in the automation of more than 35 Amazon warehouses across Europe. Despite occasional challenges in the supply chain, we are proud to have delivered all projects to date on schedule.

If you would like to learn more about warehouse automation, available sorter configurations, or other services we offer, we warmly invite you to contact us.