Step up to smart warehousing with IoT-based technologies

By Knud Kegel, VP Product, EMnify. 

Disrupted demand cycles, supply bottlenecks, the semiconductor crunch and petrochemical shortages. It’s been a rough ride for many in manufacturing and logistics. Yet the UK manufacturing sector is beginning to see improvements. In February, activity began to accelerate due to an increase in raw material availability and some easing of the supply chain, according to IHS Markit.

Yet, throughout the various challenges, those businesses that used smart warehousing and IoT-based connectivity technologies have had a clear advantage over those that didn’t. If you’re still considering your smart warehousing options and your routes to connectivity, there are many benefits to be enjoyed.

Smart warehousing is essentially business automation. And, like other forms of business automation, it will improve productivity and save money for your business. Smart warehousing paves the way for newer, more efficient business models, where the IoT can be used to streamline and optimise existing warehouse processes. Sensors, gateways, routers, applications and platforms are all operating together, relying on IoT connectivity to power seamless data communication that allows your business to make faster decisions. Here are three ways that you can use IoT-based technologies to achieve smart warehousing and manufacturing efficiencies.

Autonomous robots for accuracy and production line flexibility

Autonomous sorting robots are a key supply chain innovation, and IoT connectivity allows them to become collaborative, communicating with and sensing other robots and endpoints. They detect the layout of their immediate environment, using sensors and cameras for navigation. Packages are classified, and guided through the corresponding output line, transferred to outbound goods. Autonomous sorting robots can also be utilised on a mezzanine, accessing entry channels and navigating multiple levels through to exit ramps, moving goods straight to the shipping area. 

There are three main advantages to using mobile robots in smart warehousing, namely flexibility, accuracy and connectivity.

Flexibility and quick implementation are possible as the robots use artificial intelligence and machine learning for decision making, adapting to changes based on information within the environment. As an example, they can differentiate between a permanent obstacle, such as a shelf, and a temporary obstacle, such as a transport trolley, and take immediate action accordingly.

Accuracy is high on the list of advantages of autonomous sorting robots. Advances in navigation technology, sensor technology and image processing have increased their safety and dexterity when performing tasks.

For connectivity, autonomous robots are integrated into other systems throughout the warehouse ecosystem. Warehouse and technology personnel can tap into data from autonomous robots, improving their operations and harnessing an additional data source to interrogate logistics processes taking place across the warehouse. The ideal connectivity option here is 5G, which can also deliver real-time data on machine output and production processes, drastically increasing wider visibility, productivity and sustainability on the shop floor.

Driverless transport systems for increased productivity

Driverless transport systems (DTS) are another option to control the flow of raw materials in the factory ecosystem, bridging longer distances when compared with autonomous sorting robots, while maintaining flexibility and site efficiency. 

Although they may appear similar to autonomous robots, the main difference is that DTS vehicles use an automatic, pre-programmed system, and mobile autonomous robots are fully self-directed. While a DTS moves along a predefined route, navigating by laser or wire control, autonomous robots constantly evaluate their surroundings, adapting their route using artificial intelligence. The load-bearing capacity of the two options is also an important difference. Autonomous mobile robots normally work with boxes or light packages, while DTS tend to be used for pallets. 

DTS speeds tend to range around two to three miles per hour in environments with passenger traffic, yet higher speeds can be achieved in fully automated areas. In practice, the load capacity of a single driverless transport vehicle can range from three to 50kg. 

When it comes to flexibility, DTS delivers far more than other automated transportation systems. It’s easily integrated into existing environments, regardless of the nature or the needs of the location. It’s also suited to the transportation of a wide range of different loads. Plus, entire conveyor systems can be completely relocated during operation. And, unlike its human counterpart, a driverless transport vehicle doesn’t need to take breaks. It’s always ready for use, ensuring continuous supply whenever and wherever it’s needed.

Image recognition for higher product quality

There are many more ways to start implementing smart warehousing technology, beyond autonomous robot technology or a DTS. If you’re not yet ready to progress in that direction, image recognition is another way to prepare your business for the future. 

Image recognition systems support your production line employees by recognising components and responding or guiding employee actions. These systems provide a display screen so that operatives can see which component they need to collect from which compartment and in which order. As a result, your workforce stays alert and operating to their full capabilities. And when an error does occur, the image recognition system immediately notifies the employee and advises on the remedial action to be taken. 

When implemented as part of a connected IoT deployment, image recognition systems provide a valuable failsafe mechanism, particularly when part numbers consist of long strings of numbers and complex symbol combinations, or different parts have a similar form factor. Visual, positive feedback for the proper completion of tasks can allow team members to maintain concentration, even towards the end of a heavy shift. That means an increase in product and processing quality, reducing potential errors that could lead to incorrect consignments and a fall in customer satisfaction. From an employee perspective, it’s also a more relaxed, streamlined and straightforward experience, improving the well-being of your team as well.

Another benefit of deploying an image recognition system is that it allows for comprehensive visual documentation of the work carried out. Production processes can be reviewed in detail and any errors can be identified and remedied, with your business also able to build in safeguards to defend against any future occurrences.

A smart future for manufacturing and warehousing

When you start to move down the smart route, things like real-time monitoring, operational decisions and instantaneous changes become so much easier to implement. Human error is reduced considerably, and safety and security are heightened. To deliver the advantages, you need to build your IoT around a robust and reliable digital network. With cellular IoT connectivity, you can monitor, manage and control all aspects of your IoT network, ensuring you stay one step ahead with a fast and reliable communication platform.