Supply Chain

Is There Still a Place for the Humble Conveyor in the Modern Warehouse?

Guest blog by Giovanni Stone from MHI Member Company Daifuku Intralogistics Company

The material handling industry is experiencing an influx of new and exciting technologies that often promise to revolutionize the modern warehouse. As warehouse professionals, it is up to us to determine which technologies can meet our business objectives. The industry has experienced various technological developments over the decades, with some becoming popular and others fading away. In recent years, Autonomous Mobile Robots (AMR’s) and AGV’s have surged into the marketplace. This technology can broaden the application of automated systems and may overlap the application of traditional technologies. This overlap may have us asking, how do conventional technologies like conveyors still provide value within the modern warehouse. This article will explore how new technologies, like AMR(s) compares to conveyors, the more traditional warehouse automation.

Assessing the Viability of Conveyors in Warehouse Automation: Is it Still a Viable Solution?
Throughout history, humans have consistently devised innovative ways to transport goods from one location to another. Conveyors have been used in some form for more than 230 years.

Things really started to pick up during the industrial revolution with Henry Ford famously using conveyors to boost productivity on his assembly lines. Today modern conveyors have evolved into the workhorse of the modern intralogistics supply chain. The evolution of conveyor systems serves as a testament to our ingenuity and our desire and need to move massive amounts of goods throughout our society. Modern conveyors can move materials as small as a single grain of rice to massive amounts of earth and rock in the mining industry.

In intralogistics, conveyors can handle various package types including polybags, cartons, totes, trash, etc. Conveyors have evolved from simply transporting materials to providing sortation to support business processes. One major advantage of conveyor is the variety of modules that have been developed, and the staggering amount of research and development that has been devoted over the past 100 years. Simply today, conveyor is still reliable, fast, and well established in the material handling industry.

Hence, the ability of a conveyor system to reliably connect the different parts and areas of a modern warehouse is unparalleled. These systems can provide more throughput and routing packages more reliably to more operations than any other technology.

Although, conveyors do not come without restrictions, some of the biggest drawbacks to a conveyor-based solution is space and flexibility. The conveyor and all support structures required to keep it in place can eat up space quickly. Even more so with the space that it consumes, conveyor is bolted in place and the layout becomes fixed. New flows or processes may require significant effort include. This can be challenging in a dynamic material handling environment.

Let us take a closer look at AMR(s) to see how they provide a new perspective on the industry.

Expanding the reach of Automated Transportation and Sortation with Autonomous Mobile Robots (AMRs)
The autonomous mobile robot, commonly known as an AMR are highly advanced robots that can navigate its surroundings and handle tasks without the need for human intervention.

Unlike more traditional Automated Guided Vehicles (AGVs), AMRs do not require pre-defined tracks. Instead, they use a combination of real-time sensors, mapping technologies such as Simultaneous Localization and Mapping (SLAM), and Artificial Intelligence (AI) to move around a facility in a more dynamic and flexible way. By using these advanced technologies, AMRs expand the possible applications for automation and bring significant benefits to various industries.

One of the biggest advantages of an AMR system over a traditional conveyor solution is flexibility. AMR’s do not require tracks or large amounts of fixed equipment. An AMR can move freely through a large open space, allowing customers to move products throughout the building fewer restrictions on space. AMR’s can also interact in space with people. No need for safety fencing or fixed travel paths.
Another key benefit of an AMR system is scalability. With an AMR system you can start with a single robot and simply add additional robots to increase productivity. This allows customers to get into a system with a smaller lower entry cost, which makes it an ideal choice for small and mid-sized businesses that want to automate their operations without breaking the bank.

Like any technologies, there are limitations to AMR(s) and how they can be implemented. One disadvantage is instant speed. While you can scale a system with multiple robots there is a limit to how much volume can be taken away or delivered to a specific point. Another concern is how new some of the features are in some of these systems. While AMR’s have shown in recent years that they are a proven and reliable solution, in many cases we do not always have examples of specific case studies for a particular solution. Often customers may feel they are truly getting into cutting edge technology developments with the experience of iterative testing.

AMR(s) do have an ongoing cost beyond the initial purchase price. Lucas Systems estimates that the annual cost for maintenance for an AMR is 20% of the capital cost. Batteries will need to be replaced around the 5-year mark, and that is a significant cost depending on the fleet’s size. There are other costs to be considered such as software updates, system reconfigurations, and training.

Finding the Right Balance: Traditional vs. Modern Technologies in Warehousing
In conclusion, when comparing traditional conveyor systems to autonomous mobile robots (AMRs) it’s important to consider the specific needs and objectives of your warehouse operations. While traditional conveyors offer reliability and efficiency for certain applications, AMRs provide flexibility and adaptability to dynamic warehouse environments. Ultimately, a hybrid approach that combines the strengths of both technologies may offer the most comprehensive solution for optimizing productivity and efficiency in warehouse operations.

Volume/Throughput

  • Package/Tote Conveyor: Good for medium to high volume operations like store distribution and high-volume e-commerce
  • AMR(s) for Picking/Package Handling: Good for low-medium volume operations

Buffer

  • Package/Tote Conveyor: Can accumulate easily between processing areas. High in system buffer capacities can be achieved.
  • AMR(s) for Picking/Package Handling:  AMR(s) need to interface with rack or conveyor for accumulation

Sortation

  • Package/Tote Conveyor: Can sort to high speeds of 700+ FPM/280+ CPM
  • AMR(s) for Picking/Package Handling: Low to medium volume sortation capacity due to vehicles congestion at higher sort rates.

Flexibility

  • Package/Tote Conveyor: Fixed Automation – Build for peak, less flexible for a 350changing business
  • AMR(s) for Picking/Package Handling: Flexibility – Can add vehicles for peak, can adapt to changing business

Infrastructure Requirements

  • Package/Tote Conveyor: Need to consider fixed paths, roof supports, mezzanines
  • AMR(s) for Picking/Package Handling: Less infrastructure requirements but can require mezzanines, minimum floor quality standards

Maintenance

  • Package/Tote Conveyor: Preventative maintenance provides long life.
  • AMR(s) for Picking/Package Handling: Battery replacements costs are relatively high and will occur about every 2K+ cycles

Productivity

  • Package/Tote Conveyor: Highly reliable and can run for 24 hours a day.
  • AMR(s) for Picking/Package Handling: Robots do need to charge. Robots can strategically charge to avoid delays

Training

  • Package/Tote Conveyor: Simple interaction
  • AMR(s) for Picking/Package Handling: AMR’s do have user friendly interfaces but do require some training.

Project Timeline

  • Package/Tote Conveyor: Depends on size of solution but can be 8-12 months
  • AMR(s) for Picking/Package Handling: Typically, less than 6 months to deploy a system after design approval. Software will be the long lead item.

By integrating these advancements, you can stay up-to-date and improve your warehouse operations while keeping your business running smoothly.

Finding the right material handling solutions can significantly improve the efficiency of your warehouse operations.

Companies like Daifuku Intralogistics America are able to offer the solutions best fit for your supply chain needs. To learn more, visit mhi.org/members.

facebookShare on Facebook
TwitterTweet
.