From 0 to 100 % automation in intralogistics

Striking the right balance: from purely manual to fully automatic

Increased efficiency, lower costs and process optimization – the positive features of industrial automation are always accompanied by fear of losing one’s job. Which means we must be discriminating in our approach: What degree of intralogistics automation is sensible and justifiable for my business? We envisage different levels of expansion, from the innovative, manual warehouse to full automation controlled by artificial intelligence.

The call for automation and what can actually be achieved

The manufacturing industry in Europe is facing increasing challenges such as cost pressure, a shortage of qualified personnel caused by an increasingly ageing population, and rapidly changing demands. This requires flexible and efficient production processes. So it is hardly surprising that manufacturing companies are increasingly looking at automation projects. But what does the automation of intralogistics mean for individual companies and what is the impact on employees? Do the economic benefits of automation always come at the expense of jobs? Our answer is no! Automation in intralogistics brings many opportunities.

One aim of automation is to pay more attention to employees’ skills and make the most of them. Monotonous, physically strenuous, or dangerous tasks can be done by machines instead. This relieves the strain on the individual, who can then be deployed elsewhere to generate value. Automation changes our daily work but does not replace it.

Another aim of automation in intralogistics is to improve efficiency and lower costs. Automation can increase quality, process reliability, and production speed. This in turn helps manufacturing companies stay competitive, and also lets them work and generate value in Europe.

Quality assurance with work stations using integrated image processing systems

At Jerich International, quality checks are made on vehicle body parts at a state-of-the-art work station equipped with an integrated image processing system, which helps the employees to check the parts. Actual images are compared with expected images. Thanks to real-time feedback, quality deficiencies are immediately identified and employees are given optimal support while working.

The ivii.smartdesk provides employees with real-time feedback on the correctness of each work step. This prevents errors, and what’s more, the work station seamlessly documents the work processes. The costs of customer complaints or correcting errors are fully eliminated.

Process optimization thanks to intelligent redPILOT software

redPILOT optimizes processes in the warehouse, even if no automation technology is being used. The software is modular in design and intended to ensure optimal resource management. Cost- and performance-based schedules can be created for all employees at a simple click of a mouse. Planned, current, and ideal performance and costs are evaluated across all processes to identify where there is room for improvement. As the degree of automation increases, the mechanical resources are integrated into redPILOT. The software also helps to evaluate when it makes sense to increase the degree of automation in the warehouse.

Open Shuttles supply work stations flexibly and quickly

At an aircraft manufacturer in Bremen, Germany, our autonomous mobile robots, the Open Shuttles, handle the transport of calibrated tools to the manual work stations in manufacturing. Open Shuttles bring just-in-time automation to material transport, from the tool crib to the work stations, and allow employees to work more efficiently. Thanks to autonomous navigation, our Open Shuttles can also move in mixed traffic between racks, forklift trucks, and carriers.

Efficient handling of various logistical demands with an OSR Shuttle™ at Terberg

Several processes at Terberg Benshop BV have been centralized in one storage system in order to handle an increasing number of picking orders. The small parts are stored in the OSR Shuttle™ and presented to the ergonomic Pick-it-Easy Flex work stations as needed. Picking is conducted here for manufacturing, the assembly line, or for the shipping of spare parts, according to the order. All these processes are mapped by the KiSoft software, the brain of the solution.

Innovative logistics solution at Pankl makes it possible to implement a zero defect strategy

Maximum quality and end-to-end traceability are the basic requirements for implementing Pankl’s zero defect strategy. An automated small parts warehouse supplies the assembly work stations. Modern image processing technology checks every work step when assembling transmissions and ensures error-free assembly as well as end-to-end traceability. A comprehensive KNAPP software solution tops off this mix of technologies.

MFC: a highly flexible, scalable automation solution in miniature

E-Grocer MFC for the food retail sector is an example from outside the manufacturing industry. It uses the OSR Shuttle™ Evo as the storage and picking system. The orders are fulfilled semi-automatically at the adjacent Pick-it-Easy work stations where the employees are guided through the picking process. The Open Shuttles then handle the picking orders directly and take them to the flow racks in the shipping area. They sort the containers automatically, according to a range of criteria. The specifically developed solution is used around the globe by well-known food retailers, such as Woolworths, Albertsons, and Carrefour.