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Types of Warehouse Automation
Types of Warehouse Automation
There are many warehouse technologies to consider when designing or retrofitting a distribution center, from basic traditional equipment to more advanced warehouse automation solutions.
The objective of this page is to provide insight into the variety of more advanced technologies to consider within the warehouse automation industry when designing an integrated, automated solution.
Quick Links to Content:
- Automated Storage & Retrieval Systems (ASRS)
- AGVs & AMRs
- Conveyor & Sortation Equipment
- Mixed Case Sequencing & Palletizing
- Additional Physical Warehouse Automation Systems
- Digital Warehouse Automation Systems
Types of Warehouse Automation
Types of Warehouse Equipment
There are a multitude of warehouse equipment alternatives to consider. The key is to determine the right fit of technologies to deploy based on the unique volume and material handling characteristics of the warehouse operation. As examples:
- Product transport through the warehouse via forklifts, pallet jacks, and conveyor systems can be replaced with Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs).
- Product storage in static rack and forward picking locations can be replaced with Automated Storage and Retrieval Systems (ASRS) and AMR shelving units.
- Individual item picking can be performed by a robots with articulated arms with pick and place functionality.
- Unloading and unloading trailers, palletizing and depalletizing cases, labeling and packaging products can also be highly automated.
- Further, orchestrating the movement of goods across multiple technology platforms within the warehouse can be done via advanced automation software.
Examples of Warehouse Automation
Warehouse Automation Examples & Considerations
Automation has become more easily justifiable than in the past, and the industry is witnessing large scale deployment of Automated Storage and Retrieval Systems (ASRS), Automated Guide Vehicles (AGVs), Autonomous Mobile Robots (AMRs), and many other types of robotic systems, such as automated piece picking robots, put-walls, palletizers, de-palletizers, and container unloaders. And, continuing advancements in lower cost, mobile, scalable technologies are enabling facilities with lower or more variable volumes and/or smaller in size to also justify automation. Key characteristics to consider when pursuing warehouse automation should include product handling type, volume, scalability, and the business case compared to viable alternatives.
Automated Storage & Retrieval (ASRS)
Unit Load Crane Based
Case/Bin Shuttle Based
Unit Load Crane Based
Suitability:
- Dense cubic utilization of high volume pallet movement
Characteristics
- Pallet In / Out
- Mature Technology
- High Investment
- Moderate Speed
- 60’+ tall buildings
- Low Flexibility
Sample Suppliers
- Daifuku
- Dambach-Lagersysteme
- Frazier
- Interlake Mecalux
- Swisslog
- System Logistics
Mini Load Crane Based
Case/Bin Shuttle Based
Unit Load Crane Based
Suitability:
- Case picking slow to moderate volume SKUs
- Moderate throughput capacity
- Case buffering and order sequencing
Characteristics
- Case In / Out
- Mature Technology
- Moderate Investment
- Moderate Speed
- Low Flexibility
Sample Suppliers
- Daifuku
- Dambach-Lagersysteme
- Dematic (KION)
- Interlake Mecalux
- System Logistics
- Swisslog
Case/Bin Shuttle Based
Case/Bin Shuttle Based
Robotic Cubic Bin Based
Suitability:
- Each or case picking slow to moderate volume SKUs
- High throughput capacity
- Case buffering and order sequencing
Characteristics
- Case In / Out
- Bin Replenished / Bin to Workstation for Each Picking
- Maturing Technology
- High Investment
- High Speed
- Limited Flexibility
Sample Suppliers
- Daifuku
- Dematic (KION)
- Knapp
- SSI Schaefer
- Swisslog
- TGW
- Vanderlande
Robotic Cubic Bin Based
Robotic Cubic Bin Based
Suitability:
- Each picking slow to moderate volume SKU
- Dense cubic space utilization
Characteristics
- Bin Replenished / Bin to Workstation for Each Picking
- Emerging to Maturing Technologies
- Moderate Investment
- Moderate to High Speed
- Scalable
- Moderate Flexibility
Sample Suppliers
- AutoStore
- Exotec
- Intellistore
- Ocado
- OPEX
- Urbx
Vertical/Horizontal Based
Suitability:
- Each picking small, slow volume SKUs
- Moderately low ceiling heights
Characteristics
- Tray or Bin Replenished / Tray or Bin Cycled to Workstation for Each Picking
- Mature Technology
- Moderate Investment
- Slow to Moderate Speed
- Scalable
- Moderate Flexibility
Sample Suppliers
- Kardex
- Modula
- White
AMR Based
Suitability:
- Each picking slow to moderate volume SKUs
- Highly variable demand
- Uncertain long term demand forecast
- Low capital budget
Characteristics
- Case, Totes, or Shelves to Operator
- Emerging to Maturing Technologies
- Scalable Investment (RaaS is common)
- Slow to Moderate Speed
- Scalable; High Flexibility
Sample Suppliers
- Geek+
- Grenzebach
- GreyOrange
- HAI Robotics
- Scallog
Pallet Shuttle Based
Pallet Shuttle Based
Pallet Shuttle Based
Suitability:
- Pallet in, pallet out operation
- Deep dense storage of many same-SKU pallets
- Several thousand palletized products in inventory
- LIFO or FIFO
Characteristics
- Pallet in / out on one or both sides
- Shuttle moves pallet to/from end positions pick up and drop off locations
- Very high cubic space utilization
- High cost per pallet position
- May be integrated with vertical lifts
- Moderate Flexibility
Sample Suppliers
- Apex
- Daifuku
- Erofork
- Frazier Industrial
- Interlake Mecalux
- MOVU
- Swisslog
AGVs & AMRs
Automated Guided Vehicles (AGVs)
Suitability
- Pick up, transport, putaway, and drop off of pallets and stable large unit loads
- Tugging or towing wheeled containers
- Multi-shift, high volume pallet movement operations across common "A" to "B" fixed movement paths
- Scarcity or high expense of labor
Types of AGVs:
- Unit Load
- Counterbalanced Forklift
- Double Wide
- Straddle
- Reach Truck
- Very Narrow Aisle
- Tower / Tugger
Navigation
- Magnetic Tape
- Laser
- Wire
- Optical Cameras
Sample Suppliers
- Daifuku
- Dematic (KION)
- E80 Group
- Hyster-Yale
- JBT
- Jungheinrich
- Linde
- KION
- KUKA
- Rocla
- SSI Schaefer
- STILL
- Swisslog
- System Logistics
- Toyota Material Handling
Autonomous Mobile Robots (AMRs)
- Suitability
- Goods to person (GTP) shelf-based each picking
- Persons to good (PTG) aisle-based each picking
- Small goods unit sortation
- Payload transport
- Modest to high volume multi-shift operations
- Scarcity or high expense of labor
Types of AMRs:
- GTP Shelving and Product Movers
- Collaborative Pick & Replenishment Assistants
- Shelf Lift
- Conveyor Transfers
- Tilt Tray Sortation
- Stacker Trays
- Shrink Wrapping
Navigation Guidance
- LIDAR (Laser)
- 2D and 3D cameras
- Geo Fencing
- Odometry & Localization
- Obstacle Detection & Avoidance
Sample Suppliers
- 6 River Systems
- Addverb
- Agilox
- Balvo
- DS Automation
- Fetch Robotics
- Geek+
- Grenzebach
- GreyOrange
- HAI Robotics
- IAM Robotics
- Junheinrich (Magazino)
- Locus Robotics
- MiR
- OTTO Motors
- Quicktron
- Rockwell Automation (OTTO)
- Starnus
- Swisslog
- Tompkins Robotics
- VisionNav Robotics
- Vecna Robotics
- Waypoint
For an exhaustive list of AMR providers and their solutions, please visit the Mobile Robot Directory.
Conveyor & Sortation Equipment
Conveyor and Sortation Equipment
Suitability
- Transport of conveyable goods throughout a warehouse across variable distances and vertical heights
- Merging and sortation of goods from multiple source points to multiple destination points
Types of Equipment
- Inbound/Outbound Extendable/Telescopic Conveyor
- Transport and Accumulation Conveyor
- Linear and Oval Sortation
- Spirals and Curves
- In-Line Label Printer and Applicators
- Control Panels (associated with equipment)
- WCS/WEC (associated with equipment)
Sample Suppliers
- Ambaflex - spirals
- Beumer - sortation
- Dematic (KION) - multiple types
- EuroSort - sortation
- FORTNA - multiple types
- FMH Conveyors - extendables
- Honeywell Intelligrated - multiple types
- Hytrol - multiple types
- Interroll - multiple types
- Panther Industries - print and apply
- Ryson - spirals
- TGW - multiple types
- Trew
- Vanderlande - multiple types
Sample Sortation Videos
Mixed Order Sequencing & Palletizing
Example | ACPaQ | Swisslog
Swisslog offers an integrated solution called ACPaQ comprised of pallet layer picking, carton descrambling, tray loading, case buffering and sequencing, and robotic palletizing.
Example | AMCAP | Dematic
Dematic offers an integrated solution called AMCAP comprised of pallet layer picking, carton descrambling, mini-load case buffering, sequencing, mixed case palletizing, and stretch wrapping.
Example | Vertique | System Logistics
Highlights:
- Designed to discrete set of volumes, velocities required, package configurations, etc.
- More suitable for low SKU count environments that don’t require a large buffering system
- Relatively easy to supervise associates as activity is largely concentrated in a small footprint
Example | Order Picking Machinery (OPM) | WITRON
Highlights:
- This fully automated case picking system was developed to build store-friendly order pallets / roll for both dry goods and fresh / frozen goods.
- The heart of this flexible system is the automatic loading of an order pallet / roll container with cases of various sizes and weights.
- Loading is accomplished using a highly dynamic Case Order Machine (COM).
- Unlike the typical robotic gripper and suction system, cases are carried and pushed during the entire material flow process, thereby allowing an extremely high percentage of items to be handled within the system.
- A proprietary stacking algorithm determines the optimal stacking sequence and loading pattern based on case weights, case sizes, case crushability, and store planogram logic. This “pack pattern” software allows order pallets to be densely packed in a store-friendly sequence, without any case damage.
Additional Physical Warehouse Automation
Humanoid Robots
Humanoid Robots
- Humanoid robots offer the wide flexibility of human-like movement unlike any other warehouse automation solution and may be suitable for laborious, menial, and/or ergonomically challenging tasks otherwise performed by warehouse workers.
- Emergence in warehousing is relatively new but may grow rapidly in the years to come
Sample Humanoid Developers
Trailer / Container Case Unloading
Trailer / Container Case Unloading
- Unloading loose cases from trailers and shipping containers is a arduous labor task
- Such labor can be significantly reduced or eliminated with semi or fully automated equipment
Sample Suppliers
- Boston Dynamics - Stretch (fully automated)
- Dexterity - DexR (fully automated load & unload)
- Gorbel - Destuff-it (semi-automated assistance)
- Mujin - Truck Bot (fully automated)
- Pickle Robot Company (fully automated)
Packaging Equipment
Packaging Equipment
- This category includes cut to size corrugation, carton erectors, void fill, bubble wrapping, and case sealing.
- Automated packaging equipment can reduce labor cost, parcel DIM weight charges, and damages associated with shipping individual cases to customers.
Sample Suppliers
- 3M
- Accutech
- Cleveland Equipment
- CMC
- Lantech
- Packsize
- Ranpak
- SealedAir
- Sparck Technologies
Conventional & Robotic Palletizers
Conventional & Robotic Palletizers (& Depalletizers)
- Generally, there are two types of palletizers - conventional and robotic
- Cases fed to a conventional palletizer are rotated and organized by layer and then placed, layer by layer, onto a pallet. They are ideally suited for high speed palletization of cases with minimal variation in package size
- Robotic palletizers grip one or more cases at a time then place onto a pallet using an articulated robotic arm. These are often used in lower speed environments and when package size is more variable from SKU to SKU
- The same robotic palletizer technology may also be used for depalletizing
- Note, several companies source the OEM technologies, may apply proprietary software, and specialize in customizing end-customer solutions
Sample OEM Suppliers
- Columbia - conventional OEM
- TopTier - conventional OEM
- ABB - robotic OEM
- Doosan - robotic OEM
- Fanuc - robotic OEM
- Kawasaki - robotic OEM
- Universal Robots - robotic OEM
Robotic Piece Pick & Placement
Robotic Piece Pick & Placement
- Robotic pick and place technology utilizes robots with articulated arms, advanced vision and sensing systems, and customized attachments to grip an individual item and then place to a destination point within "arms reach" of the robot
- Frequently, such solutions are suitable at ASRS pick stations picking product from donor bin to destination totes.
- When picking from multi-SKU bins or totes, the robot must maneuver the item to a barcode reader prior to proper placement
Sample Suppliers
- ABB
- Berkshire Grey
- Covariant
- Daifuku
- Dematic
- Dexterity
- Fanuc
- Fizyr
- Kindred
- KUKA
- Mukin
- Omron
- OSARO
- Plus One Robotics
- RightHand Robotics
- Universal Robots
- Yasakawa
Gantry Robot Systems
Gantry Robot Systems
- Overhead gantry robots move in linear X, Y, Z cubic directions to automate the pick and placement of uniform stacks or units of typically large times (e.g. tires, milk crates, cases).
- Such systems allow for dense floor storage and picking within a secure, confined area in the warehouse
Sample Suppliers
- Cimcorp
- Sage Automation
- Cassioli
Digital Warehouse Automation
Warehouse Management Systems
Warehouse Management Systems (WMS)
- A WMS manages operational processes, receipt management, order management, and inventory management within a warehouse or distribution center (i.e. receiving, putaway, replenishment, picking, packing, shipping, and inventory control).
- More advanced systems provide extended functionality (e.g. waveless planning, yard management, dock scheduling, slotting optimization), decision-support capability, and tight integration with automated equipment.
Sample Suppliers
- Blue Yonder
- Infor
- Koerber
- Manhattan Associates
- Oracle
- SAP
- Softeon
- SSI Schaefer
- Tecsys
Warehouse Execution Systems
WES/WCS Software
- As the level of automation grows in a warehouse, the software emphasis shifts from people-centric WMS processes to materials handling integration (WCS) and, optimization (WES).
- A WMS manages orders, inventory, and warehouse processes whereas a traditional warehouse control system (WCS) executes the physical movement of goods throughout a warehouse material handling system, such as conveyors, sorters, automated storage and retrieval systems, etc.
- A WES is generally an extension of a WCS with additional business logic that blends and adds upon the traditional capabilities of a WMS and WCS.
Sample Suppliers
- Bastian - Exacta
- Dematic - Dematic IQ
- Fortna - FortnaWES
- Honeywell - Momentum
- KPI - Kommand Performance
- New Dawn - Intelligent WES
- Numina - RDS
- Softeon - Softeon WES
- SSI Schaefer - WAMAS
- Swisslog - SynQ
- Tech King Operations - SmartMoves
- Vargo - COFE
- Westfalia - Savanna.NET
Multi-Robot Orchestration
Multi-Robot Integration & Orchestration
- Intelligent middleware (generally with pre-built APIs) sitting between multi-platform automated robots, sensing devices, and warehouse execution software
- The software assigns and coordinates work, and monitors performance across diverse, heterogeneous fleets of robots and complimentary warehouse automation systems
- Ideally leveraged in lieu proprietary, single-supplier platforms to enable agnostic solution scalability and/or replacement across the warehouse as operational needs change
Sample Suppliers
- Accelogix
- CoEvolution
- Formant
- GreyOrange
- InOrbit
- MacGregor Partners
- Rapyuta
- Ready Robotics
- SVT Robotics
Unified Control System (UCS)
Unified Control System (UCS)
- An emerging capability to unify control between conventional material handling systems, robots, the WMS, WES, and WCS software
- Conceptually, it optimizes task assignments and material flow across conventional and advanced physical and digital systems throughout the warehouse
Sample Supplier
- ferag
- Koerber
Warehouse Digital Twin Simulation
Warehouse Digital Twin Simulation
Warehouse Simulation & Digital Twin
- A digital twin is a digital representation of the warehouse (e.g. activity, material movement, equipment, labor) enabling visualization, analysis, prediction, and optimization of people, processes, and technologies
- A form of digital twin technology is warehouse simulation, which is a virtual mathematical model used for the purpose of testing interdependencies between volume, variability, labor, and equipment in the flow of goods through a warehouse
- Often, simulation software is used to evaluate a conceptual or an existing warehouse design utilizing mechanized or automated equipment to evaluate throughput capacities and potential bottlenecks in the systems (e.g. conveyor and sortation equipment, AGVs AMRs)
Sample Suppliers
- AnyLogic
- Arena
- AutoMod
- CreateASoft
- Emulate3D
- Flexsim
- Logivations
- ProModel
- Rockwell Automation
- SimEvents
Warehouse Slotting Software
Warehouse Digital Twin Simulation
Warehouse Slotting
- Slotting is the process of assigning specific items to locations with the objective to balance optimized order picking and putaway efficiency with effective space utilization in the warehouse
- Fixed slotting assigns an item to a fixed location whereas random slotting assigns items to a pick zone
Sample Suppliers
- Fortna - OptSlot DC
- Manhattan Associates - Slotting Optimization (4SiGHT)
- Mantis - Advanced Slotting (DC Expert)
- Royal 4 Systems - WISE
- Slot3D
- WarehouseVision
Voice & Light Directed Picking
Voice & Light Directed Picking
- Voice picking is a hands-free system to direct and confirm warehouse operator tasks via verbal commands and interactive speech recognition
- Pick (and put) to light systems visually direct the operator using a light display at the pick or put location. The lights turn off as the pick or put is confirmed
Sample Suppliers:
- Erhardt Partner Group - voice
- Lighting Pick - voice, lights
- Lucas Systems - voice
- Mountain Leverage - voice
- Numina - voice
- Voxware - voice
- Voodo Robotics - lights
- Zebra - voice
AIDC
Automated Identification & Data Collection (AIDC)
- Utilized to identify, verify, record, communicate, track, trace, and store data on packaged or containerized items
- Leverages technologies such as scanners, barcodes, RFID tags and readers, voice recognition to automate manual activity
Sample Suppliers
- Alien
- Cognex
- Datalogic
- Denso Wave
- Honeywell
- Keyence
- Newland
- SICK
- Zebra
Scales & Measurement Systems
Scales and Measurement Systems
- Enables static or dynamic capture of weights and dimensions of items, parcels, and pallets
- Frequently integrates with barcodes readers and cameras and warehouse management software to track and manage such data
Sample Suppliers
- Cognex
- Cubican
- Falcon Autotech
- FreightSnap
- Mettler Toledo
- Parcelcube
- Rice Lake
- vMeasure
- Zebra
Automated Cycle Counting
Automated Cycle Counting
Automated Cycle Counting
- Utilizes mobile automation robots to scan or sense product barcodes or RFID tags to count inventory and monitor storage locations
Sample Suppliers
- Dexory
- Infinium Robotics
- Verity
- Vimaan