With e-commerce growth and rising customer expectations, warehouses in 2019 are under increasing pressure to deliver faster, more accurate, and more efficient operations. As the demands for rapid fulfillment and streamlined logistics continue to grow, industry leaders are looking to modernize their facilities with cutting-edge technology, innovative management practices, and employee-centered improvements.
This article explores essential trends and best practices that warehouses can implement in 2019 to enhance productivity, accuracy, and operational efficiency. From robotics and advanced analytics to sustainable practices and employee safety, these strategies can help warehouses stay competitive in an evolving market.
1. Advancements in Warehouse Automation and Robotics
In 2019, warehouse automation continues to expand, with innovations in robotics and artificial intelligence (AI) pushing the boundaries of what’s possible in warehouse operations. More facilities are incorporating automation to streamline processes, reduce errors, and meet tight delivery timelines.
Autonomous Mobile Robots (AMRs)
Autonomous Mobile Robots (AMRs) represent a significant leap forward from the Automated Guided Vehicles (AGVs) widely used in warehouses just a few years ago. Unlike AGVs, which follow fixed routes, AMRs navigate more flexibly through the warehouse using sensors, cameras, and onboard software. AMRs can adjust their routes in real-time to avoid obstacles, making them ideal for warehouses where layout changes are frequent or space is limited.
These robots are particularly useful for tasks like transporting goods, picking, and sorting, enabling human workers to focus on higher-value tasks.
Robotic Picking Systems with AI
Robotic picking systems are increasingly leveraging AI to improve accuracy and adaptability. AI-powered robots equipped with vision and motion sensors can identify, pick, and handle diverse products of varying shapes and sizes, even if they’re randomly placed. This flexibility reduces errors and boosts productivity, especially in high-mix, high-volume warehouses.
Collaborative Robots (Cobots)
Collaborative robots, or cobots, work safely alongside human employees to enhance productivity. In tasks such as packing, sorting, and labeling, cobots are effective at handling repetitive activities, allowing human workers to focus on more complex tasks. As of 2019, cobots are becoming more accessible to small- and medium-sized warehouses due to their lower cost, easy programmability, and ability to work in close proximity to humans.
2. The Power of Advanced Warehouse Management Systems (WMS)
A modern Warehouse Management System (WMS) is the backbone of efficient warehouse operations. In 2019, WMS technology has become more powerful and accessible, with advanced features that allow for seamless inventory tracking, order management, and labor optimization.
Real-Time Inventory Visibility
Inventory accuracy is critical for efficient warehouse management, and WMS technology enables real-time inventory visibility, ensuring that stock levels are always up-to-date. This helps prevent stockouts, reduce overstock, and improve order accuracy.
Integration with ERP and E-commerce Platforms
Integration capabilities in modern WMS platforms allow seamless data flow between systems, from Enterprise Resource Planning (ERP) software to e-commerce platforms. By connecting the WMS to these systems, warehouses can ensure a smoother order fulfillment process and better coordination across departments, improving overall operational efficiency.
Labor Management and Task Optimization
As labor costs rise, WMS platforms are evolving to include labor management modules that track productivity, monitor labor costs, and optimize task assignments. This feature helps managers deploy staff more effectively, reducing idle time and ensuring that critical tasks are completed on time.
Cloud-Based WMS Solutions
Cloud-based WMS adoption continues to grow in 2019, providing warehouses with greater flexibility and scalability. These systems reduce the need for significant upfront investments and can be easily scaled up or down based on business needs. Cloud WMS platforms also enable real-time updates, mobile access, and simplified maintenance, making them a popular choice for warehouses of all sizes.
3. Harnessing the Internet of Things (IoT) for Smarter Warehousing
The Internet of Things (IoT) has unlocked new possibilities for real-time monitoring, predictive maintenance, and data-driven decision-making in warehouse operations.
Asset Tracking and Inventory Management
IoT-enabled sensors embedded in inventory items or containers allow for continuous tracking within the warehouse. These sensors provide managers with real-time data on the location and condition of each item, reducing the time spent locating products and improving inventory accuracy.
Environmental Monitoring
For warehouses that store perishable or sensitive goods, IoT sensors can monitor environmental conditions like temperature, humidity, and light exposure. Automated alerts notify managers if any parameter falls outside the ideal range, allowing for quick corrective action. This real-time monitoring ensures that products are stored in optimal conditions, reducing waste and spoilage.
Equipment Monitoring and Predictive Maintenance
IoT technology enables warehouses to monitor equipment health in real-time. Sensors on forklifts, conveyor belts, and other machinery can track metrics like operational hours, vibration, and temperature. If a machine shows signs of wear or potential malfunction, managers can schedule maintenance before a breakdown occurs, reducing unexpected downtime and maintenance costs.
4. Sustainability and Green Warehousing Initiatives
As sustainability becomes increasingly important, many warehouses are adopting green practices to reduce their environmental impact. In 2019, sustainable warehousing practices benefit not only the environment but also the bottom line.
Energy-Efficient Lighting
Switching to LED lighting or incorporating motion-sensor lighting systems reduces energy consumption. LED lighting, while initially more expensive, offers lower operational costs due to its durability and reduced energy usage.
Solar Panels and Renewable Energy
Solar panel installations on warehouse rooftops are becoming more common as companies strive to lower their carbon footprints. Solar power provides a renewable energy source that reduces reliance on the grid, lowering electricity costs and promoting sustainability.
Sustainable Packaging
With the growth of e-commerce, packaging waste has become a significant concern. Many warehouses are now adopting recyclable and biodegradable packaging materials, reducing plastic use and minimizing waste. In addition, some facilities are reusing packaging materials to further reduce waste.
Electric Forklifts and Equipment
Electric forklifts produce zero emissions, making them an eco-friendly alternative to traditional diesel or gas-powered models. They’re also quieter, require less maintenance, and reduce the warehouse’s overall carbon footprint. As battery technology improves, more warehouses are expected to adopt electric-powered equipment.
5. Improving Warehouse Safety and Employee Productivity
Workplace safety and productivity go hand-in-hand in a warehouse environment. In 2019, warehouse managers are emphasizing employee safety initiatives and adopting ergonomic tools to reduce injuries, improve productivity, and increase job satisfaction.
Wearable Technology for Safety and Efficiency
Wearables, such as smart glasses, safety vests, and wristbands, are being used to monitor worker health and safety. These devices can provide real-time alerts if an employee is at risk of overexertion or in a potentially unsafe situation. For example, wearable sensors can monitor heart rates, fatigue levels, and lifting posture, alerting workers and managers if adjustments are needed.
Ergonomic Workstations and Lifting Equipment
Ergonomic workstations and tools reduce the physical strain on employees, minimizing the risk of repetitive strain injuries. Adjustable workstations, anti-fatigue mats, and ergonomic lifting devices help employees maintain comfort, which translates to higher productivity and reduced injury-related downtime.
Training and Upskilling Programs
Investing in employee training programs not only improves safety but also increases productivity. In 2019, many warehouses are prioritizing upskilling initiatives, training workers to use new technologies and enhancing their problem-solving skills. Cross-training programs also allow workers to perform multiple tasks, creating a more flexible workforce that can adapt to fluctuating demands.
Benefits of Employee-Centered Initiatives
Reduced turnover: Warehouses that invest in worker well-being see higher job satisfaction and retention rates.
Increased productivity: A well-trained and physically comfortable workforce is more productive and efficient.
Fewer injuries: Ergonomic improvements and real-time safety monitoring result in fewer workplace injuries, reducing costs associated with workers’ compensation and lost productivity.