5 Warehouse Automation & Pallet Rack Integrations that Ease Labor Challenges

Warehouse Automation — Optimize Your Workforce and Pallet Rack Connection

Pallet racking comes in a wide variety of shapes and sizes and is tailored to your inventory mix and operational needs. Workers access the racking for storage and extraction of inventory in the process of managing demand and fulfilling customer orders, but what happens when you have a labor crisis? 

Leaving products sitting on shelves and orders unfulfilled is clearly not an option. However, the solution may be as simple as integrating automation into your operation. Does that sound anything but simple? Surprisingly, a full-scale automation switch over may not be what you need; besides that, it may also be financially impossible. A few relatively easy-to-implement tools can exponentially take up the slack left by a shrinking workforce.

Warehouse Labor Challenges

• Workforce growth of over 50% in the past five years still isn’t enough to meet the needs of warehouses, DCs, and fulfillment centers.
• Labor costs are 65% of most operating budgets – only to be stressed further with a growing demand for laborers
• Hourly wages increased approximately 10% in the last year alone (2020 – 2021)
• 5% of workers on average experience an on-the-job injury

The result of these and more labor challenges is that a lot more businesses are turning to automation to meet throughput goals. Take a look at five leading automation technologies that are getting the job done.

Five Leading Automation Technologies

1. Order picking technology
2. Automated conveyors
3. ASRS – automated storage and retrieval
4. AGVs, AMRs, LGVs – automated warehouse vehicles
5. Mobile racking

1. Order picking technology

High-volume order picking can get a considerable boost in both pick speed and accuracy by implementing an order pick solution. Three popular types of order picking tech are:

• Pick-to-light – automation strips affix to each SKU location in the racking. Workers pick the correct number of SKUs by the lights and numbers on the strips.  
• Voice picking – hands-free order picking means workers can keep their heads up to watch where they are going as they move. Studies show that warehouse safety improves by 5%-20%, and pick accuracy is nearly perfect with voice picking. It is also very easy to train workers to use.
• Goods-to-person – high-volume, high-SKU selection creates an excellent atmosphere for letting the SKUs come to you via a vertical carousel storage unit or motorized shelving accessed by autonomous mobile robots (AMRs). At pick speeds of 600 per hour, AMRs can make a significant difference in your turn rates though they are battery-operated and require charging. 

Whichever technology is right for you, you’re likely to see some impressive results:

• Boost overall productivity by 25%
• Reduce error rates by 67%
• Increase storage space by 12%-20%

2. Automated conveyors

Automated conveyors are helpful for more than just simple intake and output. These applications can put your operation on a roll by severely reducing forklift activity and worker travel.

• Accumulating conveyors – control inventory flow from production through processing. Sensors within the system will stop and start the flow, which is helpful in metering or batching loads and allocating stock to storage.
• Automated repack or sort – these conveyors are the second leg in repacking and sorting operations. First, the accumulating conveyor moves incoming pallets to a staging area where items are unpacked and placed on the accumulating conveyor. From there, they flow to sorting and repacking.

3. ASRS – automated storage and retrieval

An ASRS system dramatically reduces reliance on forklifts or people to move inventory. 

ASRS systems can be semi-automated or fully automated and can carry full pallets or mini-loads, depending on your operational needs. The result? There is a labor cost reduction and fewer forklift accidents resulting in more savings from less damage, downtime, and repairs. Your ASRS system can be paired with conveyors for even less reliance on manual labor. 

4. AGVs, AMRs, LGVs – automated warehouse vehicles

While not wholly unrelated to ASRS, you might consider AGVs and AMRs, a close cousin in the world of warehouse automation. These vehicles integrate very well with pallet racking and storage applications. Here’s a quick glossary of what these initials refer to regarding automated vehicles:

• • AGVs – Automated guided vehicles – AGVs are safe and highly productive with built-in design features that prevent accidents involving rack, personnel, or both. The vehicles require manual programming but move via wire, tape, rail, or track guidance in the warehouse floor. 
  • AMRs – Autonomous mobile robots – use internal sensors (camera or lasers) and a digital map of the facility vs. a guidance system to move around safely, making them easier to integrate into your facility. The vehicles receive direction from the WMS (warehouse management software). 
  • LGVs – Laser-guided vehicles – AGV & AMR vehicles equipped with laser-guidance navigation.

5. Mobile Racking

Mobile aisle rack and shelving is a different twist on integrating automation with your warehouse pallet rack system because, in this case, your automation IS your pallet rack system. These unique storage systems sit on mobilized carriages that shift side-by-side via a mechanical-assisted handle or electric motor.

The rack systems are great for high-volume storage in a tight space because they eliminate the need for aisles. Workers need only access the one condensed storage area for an abundance of goods, and the rack allows for 100% SKU selectivity for quick, easy access to inventory.

Don’t Stumble at the Finish Line – Trust WOI for Expert Pallet Rack Installation

Installation of your project is a critical part of the plan and should be executed only by an experienced, professional crew. You are guaranteed a team committed to workplace safety and project excellence when you work with WOI. Our team members are OSHA-trained, fully licensed and insured. 

Every job –approximately 300 per year– is inspected daily for adherence to strict safety guidelines and workplace cleanliness. Our crews are pallet racking and storage solutions experts who understand the intricacies of these systems and the importance of construction integrity. With our goal of 100% Customer Satisfaction, nothing else will do.

Learn more about WOI installation in our blog – 10 Questions to Ask Before Hiring Your Next Pallet Rack Installation Crew and call today to schedule your next warehouse installation project.

Today is the Day to Plug Into Warehouse Automation

The most shocking statistic of the current state of warehousing, distribution, and fulfillment might just be that only roughly 20% of facilities have integrated warehouse automation in some capacity into their operations. That’s 80% that still can plug into the benefits these solutions provide. There’s no time like the present to get started!

The Warehouse Optimizers, Inc. (WOI) team is ready to assist you in finding a solution that works with your operation and budget. Offerings include complete turn-key projects from design to installation, including electrical and mechanical. We can schedule an on-site visit to assess your current situation, and we can sit down and listen to the challenges you’re facing… then, we’ll get to work on a plan to achieve your goals.  

We guarantee 100% customer satisfaction with our 5-Step Total Satisfaction Experience.™ As an WOI customer, we guarantee that we will:

1. Listen to your needs
2. Execute your project with special attention to your unique application
3. Stick to project timelines
4. Ensure a safe environment
5. Pay close attention to the detail of the finished product

Call today to speak with an WOI representative (865) 540-4004  or email at info@warehouseoptimizers.com. We proudly serve customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.