Optimizing logistics through warehouse mechanization

In a context where e-commerce is experiencing exponential growth, mechanization and automation have become imperative for companies seeking to remain competitive. The integration of advanced technologies makes it possible to address several challenges, including:

• Productivity gains : processes are optimized, reducing order processing times.
• Increased reliability : the quality and precision of operations are improved.
• Reduction of arduousness : repetitive and physical tasks for operators are minimized.
• Optimization of space : robotic systems allow better inventory management, by fully exploiting the height of warehouses and limiting unnecessary surfaces.

However, before embarking on a mechanization project , it is crucial to clearly define the objectives and analyze the specific needs of your warehouse. Each company has its particularities, and the reasons for mechanizing or robotizing certain processes may vary: improvement of flows, reorganization of operations or densification of space.

Preliminary analysis: an essential step

The analysis stage is often underestimated, but it is essential for the success of the project . Here are the things to consider:

• Identification of mechanizable flows : this involves determining which processes can benefit from automation.
• Modification of processes : the implementation of mechanized systems will necessarily lead to a reorganization of logistics flows. How will these changes impact your operations?
• Return on investment : the mechanization project is a significant investment. It is therefore necessary to carry out a profitability upstream.

The central role of the WMS (Warehouse Management System)

Regardless of the type of mechanized or robotic systems you choose, it is essential to ensure that your WMS can manage all flows. The WMS becomes the brain of your warehouse and controls all operations, from receiving goods to shipping orders .

Before launching your project, you will need to check several points to ensure that the WMS can:

• Effectively manage automated and robotic systems .
• Communicate the right information to other systems such as WCS (Warehouse Control System) and OMS ( Order Management System).

The idea is to create a fully interconnected , where data flows smoothly and optimizes all end-to-end processes.

Driving change successfully

A mechanization project has a significant impact on the organization of the warehouse and on the teams. It is essential to support change . It starts with:

• Involve your teams from the start of the project: employees are often in the best position to identify friction points and suggest improvements.
• Train operators : the introduction of new machines requires appropriate training to ensure that all employees can use them optimally.
• Adapt working methods : with mechanization, manual tasks decrease, but technical skills are required to monitor and maintain the machines.

Good change management is as important as the technical implementation of the project.

New performance indicators (KPI)

With robotization , new KPIs (key performance indicators) must be taken into account. The WMS must adapt to these new processes and monitor indicators such as:

• The execution speed of the robots,
• The error rate in the preparation of automated orders,
• The productivity of different mechanized areas compared to non-automated areas.

These new indicators require regular adjustments to ensure that the system is still aligned with performance objectives .

Continuous improvement process for mechanization

Successfully mechanizing your warehouse cannot be done in a single step. It is an iterative, multi-phase process that requires constant reassessment.

• Planning and preparation
  • Identification of needs : what type of mechanization is best suited to your needs?
  • Allocation of resources (human, material and financial): it is crucial to budget the project well and ensure you have the necessary teams and tools.
• Implementation
  • Acquisition of equipment : the purchase of automated systems must be made according to the needs identified during the preparation phase.
  • Installation and configuration : each warehouse has its specificities; equipment must be configured to meet your processes.

• Verification and testing
  • After installation, rigorous testing . These will make it possible to evaluate the performance of the systems and verify that they operate correctly in real conditions.
• Correction and improvement
  • Once the tests have been completed, it is time to make the necessary adjustments. If problems or efficiencies are identified, corrections must be made.

Involving your teams throughout this process is key to guaranteeing the success of the project. WMS vendor can also play an important role in adjusting the solution to best meet your needs.

Benefits and challenges of mechanization

Mechanization does not solve all problems, but it offers several advantages when implemented thoughtfully.

• Productivity gains : Automated systems, such as Goods to Man , reduce human travel, thereby speeding up order processing times.
• Optimization of storage space : robots allow inventory densification, by exploiting the height of warehouses and minimizing circulation areas.
• Operational flexibility : automated systems allow almost continuous operation, with teams working in 2x8 or 3x8 shifts, at no additional cost.
• Improved working conditions : by reducing the arduousness of repetitive tasks, mechanization contributes to the reduction of musculoskeletal disorders.

Key factors for successful mechanization

However, several factors must be taken into account to guarantee the success of the project:

• Relevance of mechanization : It is not always wise to mechanize all processes. It is necessary to assess whether mechanization provides a real return on investment for each operation.
• Hybrid approach : Many warehouses combine mechanized and non-mechanized areas to maximize flexibility. This approach makes it possible to adapt to specific products or flows.

Effective WMS : An effective WMS is crucial to seamlessly manage interactions between automated and manual areas.