The Material Handling Blog

KPIs are quantifiable metrics used to measure the success of a particular process or system. They are typically tied to specific objectives and goals and are used to track progress over time. KPIs are an essential tool for businesses to measure the effectiveness of their operations, identify areas of improvement and make informed decisions. This includes the material handling and automation industry.

As warehouse automation becomes a strategic priority for improving efficiency, accuracy, and scalability across distribution and manufacturing environments, it is important to start with the right foundation. One of the most important steps is asking the key questions that shape a successful automation solution. While automation projects often center on the equipment like automation storage and retrieval systems (AS/RS), goods-to-person (GTP) solutions, or automated guided vehicles (AGVs), the software that directs and synchronizes this equipment sits at the core of the solution. This is where a Warehouse Execution System (WES) comes into play.

Are you looking for a way to eliminate waste within your picking process? Are you struggling to achieve accuracy metrics? Does your operation suffer from constant turnover or accommodate seasonality? If any of these scenarios hit a little too close to home, a pick to light solution may be a good choice to optimize your operation! In this article, I will go over the functionality, advantages and operations best suited for this technology.

Your warehouse is running smoothly until an unexpected spike in orders disrupts fulfillment. A key shipment misses its deadline, triggering customer frustration, refunds, and cancellations. The delay escalates into a chain reaction of operational issues, leading to financial penalties, lost revenue, and reputational damage. Warehouse staff scramble to recover lost time, but the ripple effect reaches customer service teams, supply chain planners, and even corporate leadership. What should have been a routine fulfillment process turns into a costly and disruptive challenge.

The integration of emulation software and PLC represents a ground-breaking advancement in industrial automation. By leveraging emulation software, we can construct a virtual model of physical systems, allowing for real-time testing and validation. When synchronized with PLCs, the digital twin accurately replicates the behaviour of the physical system, offering valuable insights into performance, troubleshooting and optimization.

Automation in material handling is often celebrated for its ability to increase speed, accuracy and efficiency while reducing operational costs. However, one crucial factor determining the success of automation projects is often overlooked: employee adoption. Implementing new systems isn't just about integrating technology; it's about ensuring the people impacted by these changes understand, accept and embrace them. When executed well, change management bridges this gap, driving both operational success and a positive work culture.

“Let’s look at this thing from a standpoint of status. What do we got on the spacecraft that’s good? “ –Gene Kranz (Ed Harris), “Apollo 13.” There’s a lot of genius in that simple question. If you haven’t watched the movie, it’s worth a few hours of your time. The quick summary is that the mission was in serious trouble, Gene Kranz had just put on the flight director vest, and he was beginning the process of recovering not just the equipment, but most importantly, the crew of the Apollo 13 spacecraft. The genius in the question is recognizing that you have no ability to reach an endpoint if you don’t know where you are at the beginning.

“The first rule of any technology used in a business is that automation applied to an efficient operation will magnify the efficiency. The second is that automation applied to an inefficient operation will magnify the inefficiency.” Bill Gates This quote highlights a fundamental truth: the success of automation hinges not just on the technology itself but on the underlying efficiency of the processes it aims to enhance. This means that strategic planning and process optimization are essential prerequisites for reaping the full benefits of automation in warehouse operations.

From orchard to market: See how advanced automation and data analytics from RH Brown, now proudly part of Bastian Solutions, transformed a fourth-generation family business. Wenatchee, Washington, may be known as the "Apple Capital of the World," but is also renowned for its bountiful sweet cherry orchards. McDougall & Sons, a fourth-generation family-owned business, has been growing, processing, and distributing cherries and other tree fruits for decades. With Washington state producing millions of pounds of cherries annually, meeting the demand for fresh and high-quality sweet cherries is no small achievement. McDougall & Sons faced the challenge of increasing processing rates, managing peak capacity, and balancing production across multiple lines. To meet the demand for customers in both domestic and export markets, they partnered with RH Brown. Their collaboration led to significant improvements through advanced material handling automation, warehouse control software, and data analytics, transforming McDougall & Sons' operations and efficiency.

In the dynamic landscape of modern warehouses, the integration of automation has changed the way materials are handled by enhancing efficiency, accuracy, and productivity. However, the role of humans remains indispensable, bringing cognitive abilities and adaptability to the table. Striking the right balance between humans and automation in warehouse material handling is crucial for optimizing operations and maintaining a competitive edge.

Within the realm of industrial vehicle automation, the terms “dynamic path planning” and “obstacle avoidance” have recently generated buzz. On the surface, the idea of an AV (autonomous vehicle) having the capability to independently navigate around unforeseen obstacles appears to be a valuable feature. And, make no mistake, there are certainly specific applications where that feature can be beneficial. This blog post will expand on the other navigation methods and why AV OEMs (original equipment manufacturers) make the deliberate choice to use them.

As a leading systems integrator, Bastian Solutions understands material handling solutions do not come in a one-size-fits-all package. The company holds decades of experience across a broad spectrum of industry verticals and our experts partner with customers to engineer warehouse automation and material handling systems designed to achieve business objectives. Bastian is eager to exhibit at MHI’s MODEX 2024 trade show March 11-14 in Atlanta, Georgia. Booth B5619 will feature various automation and technology, along with opportunities to learn more about how Bastian can help select, implement and optimize the right material handling equipment and processes to Engineer Your Competitive Edge!