As we all know, the global industrial powers have more demand for automatic forklifts than ever before. However, when deciding to support or oppose internal logistics automation, many warehouse and logistics managers still face a long decision-making process and many obstacles. This is not always the case: Here we show how the warehouse automation process can be started "step by step" and ultimately improve productivity.
Since many logistics processes are still performed manually in small and medium-sized enterprises (SMEs), there is a high demand for driverless transportation systems (AGVS). The possibilities are diverse: automated trucks are suitable for pallet transportation, block storage, elevated storage and preservation, and automated cart solutions. Use trucks, tugs, high and low forklifts or forward trucks.
Automated logistics – easier to achieve
The buzzword "smart factory" is as old as the need for more digitization. But what does this mean when using automatic forklifts? In most cases, the answer is to achieve the following goals: better internal material flow, processes and greater security for your own employees, and reduce damage to materials and infrastructure.
Imagine that if an employee transports an average of 250 pallets in a working day, how much can an driverless forklift that can work 24 / 7 and has a short loading time be transported? In addition, it has high accuracy and no physical fatigue or disease-related efficiency loss. The fewer daily tasks you perform manually, the more resources your own employees can use to perform more complex and value-added activities.
Therefore, the main goal of warehouse automation should be to create added value for employees and companies. However, when the situation is clear and everyone wins, why are many people still hesitating? What happens if derivative costs are amortized over an average of two years?
Advantages of driverless material handling:
● optimize production: by improving efficiency, on-time delivery and 24 / 7 continuous production.
● minimize material damage: reduce the cost of damage to machines, products and infrastructure.
● higher occupational safety: benefit from advanced personnel and machine safety system.
● return on Investment: most systems recover costs within one to three years.
Easy to use manually: the automatic truck is in a state of emergency. For example, in case of WLAN failure, the truck can be operated manually and safely.
Gradual automation: reduce workload and improve productivity
Let's return to the question of whether automation as a large project requires a lot of effort. The answer is: not necessarily.
Automation can be tested through initial projects in production operations. If driverless material handling is used to work efficiently and smoothly on a "small scale", the required level of automation can be achieved flexibly.
The first step is to realize simple horizontal transportation from a to B. For example: assembly on a manufacturing machine. If this goes smoothly and a manual process is used, automatic transportation from assembly to storage can be realized. The following automation phases may include all forms of pallet handling until the final commodity is exported.
In this way, the manual warehouse has gradually become a partially automated warehouse, until the obstacle of fully automated warehouse seems insurmountable at first. With the cost advantage that the initial investment does not have to be particularly high, you can usually achieve significantly higher productivity with less initial workload.
Rather than start large projects immediately, it is more important to take small steps today.
Gradually automate and improve acceptance
The support of your own employees, work committees, safety experts and relevant stakeholders plays a decisive role in the successful implementation of automation projects. A good suggestion is to communicate the next change in the most open way possible. It's even better if employees can experience the arguments conveyed without being overwhelmed by them.
This is the case with gradual automation: small steps do not expand the comfort zone too much. Employees have the opportunity to become familiar with automation. They soon realized that their work became easier and safer, and they benefited from more flexible working hours because driverless systems could work between shifts.
Unmanned forklifts also create new space for more complex and value-added activities. Therefore, the investment in automation is always a long-term placement, but also provides greater job security.
Our tip: ask your employees to name their new colleagues. This tip increases acceptance.
Automatic forklift: project preparation is clear at a glance
Regardless of the scope of the project and whether it is an existing or new environment, careful planning and appropriate implementation are also important for smooth, first and foremost cost-effective, gradual automation. When using driverless industrial trucks for automation, the following points should be considered:
● assessment of individual needs and conditions
● record and analyze all processes on site
● consideration of existing capabilities
● create budget concepts
● conduct risk assessment
● set system specifications
● meet structural requirements / maintenance, etc
Depending on the number of steps planned, the implementation of a project takes 6 to 12 months. Systems that can be integrated into your own logistics processes alone are expected to achieve the greatest success. This can be run automatically during long-distance transportation and multiple shifts.
Seamless integration of driverless transportation system
Whether automation starts from a small step or dares to take a big step, the implementation depends on the seamless integration of automated forklift with existing systems, processes and, of course, relevant personnel.
● integration using reflectors or natural navigation systems: reflector based navigation depends on reflectors installed in the warehouse environment, while natural navigation depends on fixed objects in the room. A combination of the two technologies (dual navigation) is also possible.
● in the design of distributed contact charging station: if necessary, AGV will automatically drive to the nearest charging station, stop there and charge lithium-ion batteries independently.
Integration with process and system: in production, it can be integrated with PLC through I / O link, robot, transportation technology, etc. If the customer's own commodity management system (WMS) is integrated into automation, the existing interfaces must be seamlessly interconnected.
Integration with people: the safety system can detect man-made obstacles, reduce speed and stop industrial trucks immediately if necessary.
Integrated visualization: a clear dashboard provides a complete overview of the system: it allows real-time monitoring of activities and information about company specific KPIs.
Delivery and service patterns are a complement to automation
Anyone who intends to invest in automated forklifts to improve productivity must rely on a supplier who can provide comprehensive solutions in software, hardware and services.
Even if automation is carried out step by step, you should eventually have a reliable partner around you who can provide a complete solution from a competent source. This should include analysis, planning, implementation in existing infrastructure, complete data management and various services, such as predictive maintenance.
Speaking of predictive maintenance: predictive maintenance provides an active maintenance method based on real-time data before it may lead to expensive downtime.
Will artificial intelligence and networks shape future logistics?
As you can see, automated forklifts can improve internal material flow and significantly increase productivity. Instead of starting a big project immediately, it is more important to take small steps from today. But what about tomorrow?
To be sure, the top few giants in the global industrial vehicle ranking are actively deploying their future. It is noteworthy that stakeholders outside the industry are also eyeing and taking positive actions to intervene in the material handling of unmanned internal logistics. In any case, the future material handling is closely related to artificial intelligence, 5g and big data.
