Maximizing Warehouse Storage Capacity with Robotics, AI, Camunda, and Automation
Client Overview
National Retailer Operating Extensive Network of Distribution Centers
Business Challenge
Several Obstacles in Warehouse Operations
Capacity Constraints
Traditional racking systems were insufficient to meet growing demands, leading to the need for third-party storage services.
High Labor Costs
Manual stocking and retrieval processes were resource-intensive and prone to delays.
Limited Space Optimization
Expanding the facility horizontally was not an option, making vertical storage the primary focus.
Solution
To overcome these challenges, the client deployed a scalable Automated Storage and Retrieval System (AS/RS). The solution featured cutting-edge vertical storage technology and automated let-downs.
Vertical Expansion Using AS/RS
Utilized high-capacity cranes to store pallets vertically, effectively doubling the storage capacity within the existing space.
Optimized the layout to maximize density without compromising retrieval efficiency.
Automated Inventory Management
Implemented crane-based retrieval that replaced manual stocking methods, reducing errors and labor-intensive tasks.
Real-time monitoring and automated replenishment streamlined inventory control.
Integrated Temperature Control Optimization
Result
Goals Achieved, Workflow Improved, and Costs Reduced
Enthusiasm displayed by Client. Genuinely thrilled about substantial progress achieved in such a short time.
50% Increase in Storage Capacity
Achieved without expanding the warehouse footprint.
35% Reduction in Labor Costs
Automation reduced dependency on manual labor while improving accuracy.
Improved Throughput
Faster stocking and retrieval processes enhanced operational efficiency and reduced delays.
Scalability and Future Enhancements
The system was designed to scale alongside the client’s growth plans. Potential future upgrades include:
Predictive Analytics Integration
Utilize AI to forecast inventory peaks and further optimize storage allocation.
Dynamic Cost Allocation
Implement activity-based costing to measure storage efficiency and adjust for fluctuating demand. By embracing advanced automation, the client transformed their warehouse operations, resulting in significant cost savings and productivity gains. This case highlights the power of scalable technology for organizations seeking to optimize logistics and reduce operational expenses. For businesses interested in similar solutions, contact us to explore tailored automation strategies that fit your needs.
