Last time I started to warn for the pitfalls of (fully) automated warehouse operations. What I meant is that if you by design see it as a single black box system I sense a risk of déjà-vu of the inflexible AS/RS silos of the 70’s. Here you might say: No chance! With the flexibility of today’s equipment and integrated warehouse control system (WCS) we can adjust and tune that system both up and down to meet variations in demand.

One step back: Products will naturally fall into a couple of typical categories with regards to how easy they can be handled by automated equipment: (1) products picked in smaller quantities and with relative low pick frequency goes into high-bay storage via pallet cranes or mini-load systems and are then picked from goods-to-man pick stations, (2) nicely shaped products picked in small quantities but with high frequency goes into pick machines, (3) bulkier products and products picked in larger quantities are typically using semi-automated solutions like voice interaction, scanners etc. And depending on the hand-shake with production or with external suppliers, any of these are candidates for being cross-docked and sorted by destination without put-away and picking.

I have followed a couple of large automation projects lately, and the successful ones have taken a very holistic approach to allow for such categorization, but also to provide the flexibility needed for an ever-changing supply chain operation. A site might start as an entirely manual operation, upgrade to include RF and scanners, extend with voice interactions, and then gradually adopt MHE systems based on product category and/or turnover profiles. This can only happen if you combine these into a solution that allows implementation and change in a phased approach – by site, area or zone – with no (or little) change to the software.

So if you want to get the most out of your pool of forklift truck drivers and pickers AND material handling equipment, a proper WMS is essential to help you prioritize and balance resources. It requires support for flexible definition of warehouse profiles like layout, picking strategies, and what equipment to use. But it also requires standard interfaces to one or more WCS so that mini-loads, conveyors, sorters and robots can be staged to perform optimally and be seamlessly incorporated into the operation.

Look at the WMS as the conductor of the orchestra. The conductor keeps everything in sync and can adapt the pace and intensity to the dynamics of performing teams, individuals and instruments. But the more automation (sequencers, pre-programmed computers) you add, the more the conductor gets tied to a pre-defined – and flat – performance. So when you have automated the entire set, you won’t need the conductor, right? Well, yes - provided you don’t need to deal with dynamics or change.

And how exciting is it to sit in a live audience listening to a pre-recorded concert …

Next time:  The 101 of supply chain process automation

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