Warehouse automation and technology can improve efficiency, accuracy, and safety in your operations. But implementing them can also be challenging and time-consuming. How can you manage time when introducing new systems and processes to your warehouse? Here are some tips to help you plan, execute, and monitor your automation projects.
Before you invest in any automation or technology solution, you need to assess your current situation and identify your goals. What are the pain points and bottlenecks in your warehouse? What are the key performance indicators (KPIs) that you want to improve? How will automation and technology align with your business strategy and customer expectations? By answering these questions, you can narrow down your options and prioritize your needs.
Knowing the project's goals provides a better focus on implementing any automation. 1. Smooth Change Management Plan 2. Consider factors like seasonal fluctuations in demand and peak periods when setting deadlines 3. Contingency plans 4. Gather feedback from warehouse staff to identify any further improvements or adjustments needed. Remember that even with the full implementation, like a KPI or Sales Process, it requires a continuous follow-up.
When automating your warehouse, keep these key tips in mind: 1. Assess the entire end-to-end flow for maximum efficiency. 2. Analyze SKU and order profiles to optimize your investments. 3. Plan for scalability in both capacity and throughput. 4. Implement robust inventory management. 5. Use data analytics and real-time monitoring for informed decisions. 6. Ensure seamless integration of automation technologies. 7. Train your staff for effective operation and maintenance. 8. Consider robotics and AI-driven solutions. 9. Maintain a contingency plan for unexpected events. 10. Regularly evaluate ROI and adapt to stay competitive.
People. Process. Product. Always in this order. Every bad project I've ever been a part of has started with the product first or ignored the existing processes. And the team never talked to the actual people who had to execute daily the process & technology. What are their challenges? What is working? What isn't working? What do they wish was better? When assessing your needs, start with the frontline workers and supervisors. They know the business and the gaps in the process documentation to ship product. I guarantee your work instruction in the system is missing at least one vital step the operator knows to do that you dont. Start with your front line. People. Process. Product. In that order.
Based on my experience in Warehouse Automation, I follow the below, 1. Assessment: Begin by assessing your current warehouse operations to identify areas that can benefit from automation and technology. 2. Prioritization: Prioritize tasks and processes that will yield the highest ROI when automated, such as order picking and inventory management. 3. Set Clear Goals: Define specific goals and objectives for the implementation, such as reducing labor costs or improving order accuracy. 4. Budget Planning: Allocate a budget for technology acquisition, implementation, and ongoing maintenance.
First, delve into current processes and target points that could be improved sans automation. Improve manually; Only when you believe existing is the most effective manual process, opt for automation. Chart pain points before deciding. 1)Dig into it: Take a hard look at current warehousing & identify pain points. 2)Numbers Don't Lie: Use data to back up findings. 3)Employee Insights: Your warehouse crew knows things in&out.Talk to them to know where daily struggles happen. 4)Listen to Customers: Pay attention to customer complaints about late deliveries, mistakes, or items being out of stock which are big hints. 5)Match with Goals: Most importantly, make sure that the problems you're uncovering match up with your overall business goals
Once you have a clear idea of what you need, you can research the available options in the market. There are many types of automation and technology solutions for warehouse operations, such as conveyor systems, automated storage and retrieval systems (AS/RS), robotics, barcode scanners, radio frequency identification (RFID), warehouse management systems (WMS), and more. You need to compare the features, benefits, costs, and compatibility of each option and find the best fit for your warehouse.
With workforce challenges at the top of every management problem list right now, we must rethink how we select technology. We can no longer make decisions with a solely productivity at all costs mentality. Successful companies are researching technology that puts the wellbeing of the worker at the center of the automation. Investing in solutions that eliminate Dull, Dark, Dirty & Dangerous jobs makes your positions more attractive, makes it easier to recruit talent and even more importantly retain great people. When you invest in people-centric technology, you put the human ROI on the table with the financial ROI, improving your project value to the organization's goals.
Once you have short listed the options visit some of the clients who use the system. This is critical as it gives you a clear idea on what's working and what's not which in most cases will not be very obvious when talking to the supplier. These systems and solutions can be exorbitantly expensive as well as time consuming to implement, and the last thing you want is to continue working on old solution while trying to fix the new one whereby putting excessive strain on your resources.
1. Research: Thoroughly research automation options and technology providers. 2. Vendor Evaluation: Assess vendor capabilities, reliability, and support. 3. ROI Analysis: Calculate potential returns to prioritize cost-effective solutions. 4. Technology Fit: Identify which technologies align with specific warehouse needs. 5. Compliance Check: Ensure chosen tech complies with industry regulations. 6. Risk Assessment: Anticipate potential risks and devise mitigation strategies. 7. Change Management: Develop a plan to manage workforce transitions. 8. Data Utilization: Plan for data-driven decision-making and process optimization. 9. Scalability: Choose technologies that can adapt to future growth.
"Researching your options" when implementing warehouse automation and technology involves carefully evaluating available solutions, seeking expert advice, considering scalability and integration, and learning from others' experiences. This approach ensures informed decision-making and efficient implementation.
Cautious research plays a big role in making the most of your time during warehouse automation setup: Informed choices: Research helps pick the right technology without wasting time & money on trial and error. Seamless deployment: When you know the tech inside out, it's easier to plan & avoid surprises during setup. Mitigating Delays: Good research keeps you from changing your plans halfway through or picking tech that doesn't fit. ROI: Research helps to spend your budget wisely & avoid overspending on things not needed. Efficiency: Choosing the right tech improves processes right away, saving time & making your work more efficient. Faster learning curve: Research gets your team ready to use the tech, so they can jump in right away.
After you have selected the automation and technology solution that suits your needs, you need to create a realistic timeline for the implementation. You need to consider the factors that may affect the duration and complexity of the project, such as the size and layout of your warehouse, the number and skill level of your staff, the availability and reliability of your suppliers and contractors, the potential risks and contingencies, and the expected outcomes and milestones. You need to communicate the timeline to all the stakeholders and assign roles and responsibilities.
You should use a Go Live Checklist that maps out assignments/roles, training documentation, data conversions, cutover, testing, hardware & consumables, and post go-live plans - and each part should have an owner for accountability.
Switching from manual to automated systems shouldn't be rushed. Each phase should have a carefully determined timeline, with allowances for unforeseen delays and adjustments. The progression might encompass steps such as drafting a conceptual framework, designing the automated platform, training personnel, conducting test runs, finalizing the system, and transitioning data. It's essential to understand that this entire procedure isn't simple or something that can be expedited.
Creating a timeline for warehouse automation involves setting clear milestones, allocating time wisely, prioritizing critical tasks, monitoring progress, and maintaining open communication. This approach ensures efficient project management and minimizes delays.
One of the most important aspects of implementing automation and technology is training your staff. You need to ensure that your staff are familiar with the new systems and processes and can operate them safely and efficiently. You need to provide adequate training materials, sessions, and support for your staff and address any questions or concerns they may have. You also need to monitor their performance and feedback and provide ongoing coaching and reinforcement.
On-demand labor is a turnkey solution that allows a business to up-skill or cross train current warehouse FTE’s that need to level-up or train in another area of the operation. By alleviating your operational all-stars of their traditional, entry-level duties, you can educate them on new innovation while still meeting KPI expectations and customer demands. It takes foresight and commitment to continuous improvement to efficiently tap into the growing gig economy, but implementing new technologies in a warehouse can actually be done at the click of a button in 2023.
I was recently involved in an ERP implementation in Ohio. One of my objectives whilst on site was to train Warehouse colleagues in the use of handheld devices to move inventory in a digital manner. All Warehouse materials had been relabelled to integrate new & existing inventory into the ERP system. The devices used were running NovaCura Flow software & updated the movement of materials in real time without the need to return to a desk based computers. The training generated a lot of excitement due to the instantaneous ERP updates that were now available on a handheld device; but it also provided valuable feedback to the ERP implementation team when evaluating the input data as it highlighted missing data & further training requirements.
Effective staff training during warehouse automation involves identifying needs, providing structured programs with hands-on practice, maintaining open communication, and offering ongoing support. This approach ensures a smooth transition to new technology.
Each unit of inventory holds the same value as cash, and the level of responsibility in managing stock is on par with that of managing cash. Therefore, it's imperative for staff members to grasp and implement this philosophy fully. All responsible personnel should be educated on warehousing principles, standard operating procedures, and operational standards. Any errors committed by staff members will not only require compensation from the individual or organization but also raise doubts about the team or organization's competence. Moreover, it may risk damaging the organisation's credibility in the eyes of donors or stakeholders.
Before you launch your automation and technology solution, you need to test and evaluate its functionality and performance. You need to conduct a trial run and check if the solution meets your specifications and expectations. You need to identify and fix any errors or issues that may arise and ensure that the solution is compatible and integrated with your existing systems and processes. You also need to measure the impact of the solution on your KPIs and compare it with your baseline data.
Testing is very much important. Its a plus if your automation type has a training environment where all settings, test and trials can be undertaking before Go-Live. This enables you to evaluate the implementation of all requirements.
If you have a lot of sites and/or frequent outages due to system defects, then you should automate the execution and pass/fail reporting of repetitive tests against your WMS with the end goal of catching potentially costly defects as early as possible. Manual testing is fine for those rare edge cases, visual acceptance testing, and when conducting exploratory testing, but it can be laborious, pricey, and inconsistent if it is performed regularly to test an entire system. Whether regression or performance testing, manual testing can’t be solely relied upon to test – and in-turn reduce business risk for – warehouse management systems in a timely manner due to the overall complexity of such a deep, enterprise-wide application.
Testing and evaluating warehouse automation is crucial. Thoroughly test, continuously assess, gather feedback, benchmark, and make iterative improvements to ensure a successful implementation.
Testing and evaluation are critical steps in ensuring the success of any automation and technology solution. Here's a breakdown of the process: Test Planning: Create a detailed test plan that outlines the specific goals, objectives, and success criteria for your solution. Trial Run: Conduct a trial run in a controlled environment to mimic real-world conditions. This allows you to identify any issues or glitches in the system without impacting daily operations. Functionality Testing: Test each component and feature of the solution to ensure they work as intended. Performance Testing: Measure the solution's performance metrics, such as response time, throughput, and scalability.
After you have implemented your automation and technology solution, you need to review and improve it regularly. You need to collect and analyze data on the performance and efficiency of your warehouse operations and identify any areas for improvement or optimization. You need to keep up with the latest trends and innovations in the industry and update or upgrade your solution as needed. You also need to solicit feedback from your staff and customers and incorporate their suggestions and preferences.
Normally after Go-live or deployment, it is important to have a period for review and improvement. This is to cater for corrective actions with regards to bugs or fixes which might be required. Also to ensure some omissions are catered for. Normally 1-2 months period.
I was involved in an ERP implementation recently & I was heavily involved in preparing the local Warehouse for the Go Live Date. This involved relabelling all new & existing materials stored within the Warehouse to allow its integration into the new ERP system. I reviewed the efficiency of locating & moving materials. One Warehouse location contained a set of drawers which held numerous materials which looked good whilst reviewing the ERP data, but in real life there were around twenty-five drawers listed as one digital location, meaning that our colleagues had to search through each individual drawer to locate the material(s). My solution after reviewing this, was to improve efficiency by creating a new digital location for each drawer.
1. Performance Audits: Regularly assess the efficiency and accuracy of warehouse automation systems. 2. Data Analysis: Analyze operational data to identify bottlenecks, areas of improvement, and trends. 3. Employee Feedback: Gather insights from warehouse staff who interact with automation daily. 4. Technology Updates: Stay informed about the latest automation technology advancements. 5. Software Maintenance: Invest in software updates and routine maintenance to prevent glitches. 6. Layout Optimization: Optimize warehouse layout to facilitate smoother automation workflows. 7. Staff Training: Ensure employees are well-trained in operating and troubleshooting automation systems.
Effective Change management is key for all projects particularly those involving automation. Below steps are necessary to ensure smooth implementation. 1) evaluating the existing level of expertise 2)providing training 3) documenting processes