Getting Started with Automation

Few manufacturing and logistics companies are unscathed from the challenges that have arisen over the last few years. Disruptions in the?supply chain , the difficulty of recruiting and retaining skilled staff, plus the rapid rise in costs, from energy to raw material, have created significant operational difficulties. To safeguard margins and profitability, efficiency improvements have become an imperative, yet escalating staff turnover has led to a drop in productivity as firms struggle to find and train new employees.

Automation can transform productivity. It can create a far more efficient and engaged workforce – and a safer working environment. It can deliver the cost savings required to mitigate the impact of inflation. Yet, too many companies have held back from embracing automation due to a fear of business disruption and a lack of available investment funds.

The good news is that automation doesn’t have to be disruptive or expensive. From Autonomous Mobile Robots (AMRs) to Pick-to-Light solutions and Warehouse Execution Systems, with the right approach, companies can embrace automation step-by-step, adding value and building confidence with every small change.

Empowering Staff Productivity

The continued impact of global inflation and supply chain disruption is putting companies under enormous pressure to achieve new levels of efficiency and cost effectiveness from existing operations. And while operational effectiveness can be influenced by a range of factors, in 2023 the key issue for the majority of manufacturing and logistics operations is staff: their recruitment, retention, well-being and productivity.

The challenges associated with retaining and recruiting staff are well documented. In addition to seeking help from the government to address the estimated shortage of 60,000 drivers and warehouse operatives, many businesses have been compelled to increase salaries, with one company increasing its hourly rate for warehouse workers by 20% over the past year.

Furthermore, manufacturing and logistics companies are increasingly aware of the need to improve safety and well-being within a highly physical environment. Manufacturing, for example, accounts for only 10% of the UK workforce, yet is responsible for almost 20% of the injuries . Staff shortages put even more pressure on existing staff, increasing the risk of dangerous mistakes. Creating a safer working environment is crucial to improving productivity, and while state of the art technology such as sensor tracking bodysuits to aid posture may be out of the reach of UK small and medium-sized enterprises (SMEs), there are plenty of far more accessible automation options to consider.

Power of Automation

Automation provides a chance to address a range of operational needs, from improving productivity to transforming staff well-being and job satisfaction. Autonomous mobile robots (AMRs), for example, can reduce the time spent by workers walking around the warehouse or production facility. Indeed, AMRs are incredibly flexible, with different add-on options, such as picking arms, barcode readers, cameras or grabbing mechanisms, meaning they can be deployed in different areas of the warehouse or production site as required.

Or a company can add simple Pick-to-Light systems, where lights guide staff to the right location for each pick or put, meaning that staff are not only far more efficient, but also require minimal training to become productive. Even occasional agency staff can be as effective, efficient and accurate as long-standing employees. Warehouse Execution systems help to optimise operations and, combined with more accurate and productive picking, can improve responsiveness and help avoid costly interruptions to key manufacturing and logistics processes.

The good news is that these technologies can be added without disruption or upheaval. It is a simple process to add one or two AMRs into one area of operation to reduce the amount of time spent walking by humans. An AMR can be used at the end of an aisle, for example, to then transfer goods to the packing area or production line, allowing staff to concentrate on picking rather than walking miles around the warehouse. There are no complex integrations to worry about, an AMR can be summoned by an individual pressing a button when the goods are ready to be moved; or triggered by a simple light beam.

Cost Effective Approach

Not only can this automation be introduced seamlessly to the existing set up, but AMRs can even be trialled without cost with the right business partner. The only change that may be required is to clean up the environment: while AMRs can navigate around empty boxes and polythene shrink wrap, they will have to slow down to avoid these hazards, thus reducing their overall efficiency. Manufacturing plants with an oily floor or matting may need to be upgraded to ensure an effective human/AMR operation.

Once a company has experienced the ease with which an AMR or two can work side by side with human staff, the business may then evaluate the benefits of adding Pick-to-Light to reduce the error rate and improve efficiency. Or maybe accurate picking is the first priority, in which case adding Pick-to-Light technology would provide an immediate win. The business can then later consider adding a robot with a picking arm to take on the heavy lifting.

The inherently flexible automation model makes it far easier to build a business case for automation.?For example, robots can play an important role improving staff well-being by reducing the risk of manual handling injuries. Within retail alone, around one million working days are lost due to handling injuries every year. In addition to the impact on staff, this is a significant business cost: what is it costing the business in delayed production or order fulfilment when staff are off sick or have to be replaced by temporary staff? Using AMRs to reduce the physical demands on staff, a company cuts the risk of injury and frees up staff to undertake added value roles – such as quality assurance – and creates an environment that can appeal to a wider pool of potential talent.

Conclusion

With an incremental approach to automation, the investment can be specifically targeted at the biggest areas of business pain. The entire process can be achieved step by step, reflecting a business’ needs and investment options – with the added benefit that the entire organisation gains both incremental benefits and technology confidence.

For any company struggling to work out where to prioritise, there is help available. Working with a partner who can assess the current operational environment and suggest where an AMR could reduce human miles or take on the heavy lifting or how warehouse execution could deliver benefits can help to refine plans.

With the addition of a free AMR trial, concerns regarding both cost and disruption are addressed. Manufacturing and logistics operations can confidently explore the power of automation to support the existing human workforce, creating a safe, productive environment that becomes a more compelling career opportunity. It’s time to get started on automation.

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