The Complete Guide to Material Handling Automation for Warehouses and Manufacturing Facilities
Material handling automation combines automated technology with material handling solutions. It enables products to be moved, stored and managed with minimal human intervention to streamline operations and reduce costs. New material handling technologies ensure automation will continue to be important in warehousing and manufacturing.
The Basics of Material Handling
Material handling uses automated systems to support production, management, and storage. Standard material handling equipment includes:
Conveyors: Conveyors enable the continuous movement of bulk materials or products by creating a fixed path between machines or across facilities. Conveyor systems use rollers, chains, and belts based on the materials’ size and weight.
Sortation systems: Sortation systems sort items based on predefined criteria to optimize picking strategies and improve accuracy.
Robotic picking: Robotic picking systems are arms, grippers, and sensors that can be programmed to perform complex movements. These arms can be used for precision tasks like assembly, sorting, and picking in production and manufacturing.
Automated guided vehicles (AGVs): AGVs are mobile robots that transport materials along a fixed path. These self-driving vehicles ensure manufacturing always has raw materials on hand.
Automated storage and retrieval systems (AS/RS): AS/RS is designed for high-density storage. It uses robots to retrieve and store materials quickly and accurately.
Trends in Material Handling Technology
The material handling automation industry has many new innovations that will change picking, sorting, organizing, and transporting, including:
Artificial intelligence (AI): AI algorithms analyze vast datasets to optimize workflows, improve strategic decision-making, and enhance efficiency. For material handling automation, AI can support inventory management or determine efficient routes for AGVs.
Robotics: Robotics will continue to be a part of material handling automation. Robots can pick, sort, and palletize to reduce labor costs and increase efficiency.
Internet of Things (IoT): IoT integration with material handling automation creates smart systems that provide real-time tracking, data collection, and optimization. IoT empowers warehouse managers to make informed decisions to enhance operations.
Benefits of Material Handling Automation
Material handling automation brings many advantages to your operations, giving you a competitive edge in your industry through:
Enhanced accuracy: Material handling automation systems reduce errors by minimizing human intervention. These systems track and handle materials from start to finish, improving accuracy in areas like inventory and order fulfillment.
Scalability: These systems adapt to your business’s growth.
Increased efficiency: Automation in material handling increases productivity and efficiency. These systems streamline operations, leading to higher throughput and minimized bottlenecks.
Reduced labor and operating costs: Material handling systems pay off by bringing cost savings on maintenance, inventory, and labor. Automated systems have fewer manual interventions, wasted materials, and production interruptions.
Better worker safety: Material handling technology completes demanding, repetitive tasks, reducing fatigue, injuries, and risks for human workers.
Overcoming Common Challenges in Material Handling Automation
Though implementing automation solutions in your warehouse provides many benefits, it can introduce some challenges, including:
Safety and Compliance
Material handling automation systems must comply with safety standards to reduce the risk of accidents. Some of these standards include:
Occupational Safety and Health Administration (OSHA) regulations for material handling equipment operation and worker safety.
ISO 13849-1 for safety requirements for safety-related systems and components in material handling automation systems.
ANSI R15.06 for safety requirements for robot systems and industrial robots.
Companies must understand these standards and requirements to ensure their implementation.
Integration
Integrating tailored material handling solutions can be complex, especially with an existing legacy system. You can phase the implementation to minimize disruptions and ensure a smooth transition. An implementation partner like Solutions in Action can help you introduce the system into your operations and provide ongoing support.
Maintenance
Automated material handling systems require routine maintenance to ensure effective operation, but this can increase operational costs. Use maintenance schedules for regular upkeep, and train staff to complete these tasks.
How to Implement an Automated Material Handling System
Using an automated material handling system requires a thorough implementation strategy:
Identify areas that would benefit from automation.
Define the goals of implementing an automated system, such as increasing throughput or reducing operational costs.
Explore the types of automated material handling systems.
Create a plan for implementing the system without affecting your operations or losing critical data.
Train your staff to use the new system.
Test the system to identify and correct problems.
Implement the automated material handling system across your facility and monitor its performance.
Assess your system regularly to ensure its effectiveness and make improvements as needed.
Transform Your Material Handling Operations Today
Solutions in Action can help you learn more about how to automate material handling processes and take advantage of this technology for your company. Our tailored solutions are designed to meet your unique operational requirements and optimize your efficiency and productivity. We can further support you with our range of professional services, from consulting to turnkey installation. Schedule a consultation for your tailored material handling system by contacting us today.
