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Tag: automation

New Collaborative Robots at MODEX

Posted on by David Priestman

Schneider Electric, a global leader in digital transformation of energy management and automation, today announced the release of two new Lexium cobots (collaborative robots) at MODEX 2024; the Lexium RL 3 and RL 12, as well as the Lexium RL 18 model coming later this year. Schneider Electric innovations in robotics and motion will be on display at their booth, #B7232. From single-axis machines to high-performance multi-axis machines, the comprehensive Lexium line enables high-speed motion and control of up to 130 axes from one processor for precise positioning to help solve manufacturer production, flexibility, and sustainability challenges.

Schneider Electric goes beyond robots to provide fully integrated automation systems – digitally designed from concept to operation and maintenance. Integrating robots into the machine control solution through the EcoStruxure architecture enables collaborative data flow from shop-floor to top-floor, by connecting smart products, robots, controls, software, and services. Controlled by Modicon motion controllers, which unify PLC, motion, and robotics control functionality on a single hardware platform and integrated into of EcoStruxure Machine Expert software, it offers a complete robotic solution.

“As US manufacturing increases, the demand for smart machines is growing and customers are requiring robots with digital twin capabilities that validate machine performance to help them quickly increase production consistently, efficiently, and sustainably,” said Christine Bush, Robotics Center of Excellence Leader, Schneider Electric. “We are partnering with our customers to understand their challenges and pain points, then responding with complete, customized automation solutions – from power products and HMIs to PLCs and robotics – to simplify the process and meet their needs.”

Compatibility with EcoStruxure Machine Expert Twin, a digital twin software suite that creates digital models of real machines, allows for virtual test strategies and commissioning, as well as shortened factory acceptance testing (FAT). Digitizing these processes can reduce time-to-market by up to 50% and commissioning time by up to 60%. A 20-40% savings in investment costs can also be realized due to faster time-to-market.

Collaborative Robots

Lexium cobots are part of a full line of robotics and automation solutions developed to meet manufacturer needs across industries, including warehouse/logistics, life sciences, consumer packaged goods, and beyond. Benefits of Lexium robotics and motion solutions include:

• Fast deployment: Built on open automation standards and protocols, cobots offer flexibility, scalability, and easy third-party equipment integration. They can be easily applied to existing or new production lines in a variety of different industries.

• Streamlined integration: Enhanced computing power, open software, and networking technologies facilitate quicker assembly, installation, and maintenance of robots. A centralized architecture with a unified programming platform using open standards promotes seamless interoperability among automation systems, machines, and robots.

• Consistent output: Designed to handle repetitive tasks without errors or distractions, cobots can maintain Overall Equipment Effectiveness while manufacturing higher volumes of quality goods over shorter periods 24/7 without fatigue. This produces a consistent output with little variability over a given production batch.

• Workplace health and safety: Cobots perform well in harsh environments and can handle riskier operator tasks involving heavy weights to reduce accidents and injuries.

Amidst the rapid growth of US manufacturing, companies are increasingly seeking digital, efficient, and sustainable solutions to meet expanding output demands. Embracing Industry 4.0’s digitization, with advancements in artificial intelligence, machine learning, IoT, and digital twins, has become imperative to drive operational excellence. Software solutions are also playing a critical role in empowering manufacturers to innovate rapidly, reduce commissioning time, and stay competitive in this evolving landscape. As the industry transitions to Industry 5.0, the Lexium motion and robotics offers are poised to redefine efficiency and enable personalized autonomous manufacturing.

Read more…

Robotics and Automation Specialists Sign Long-Term Partnership

 

Intralogistics Performance is Paramount

Posted on by David Priestman

Automation solutions offer enormous potential when it comes to internal material flow. At this year’s LogiMAT trade show in Stuttgart, Germany, Linde Material Handling (MH) will be demonstrating the options available to small, medium-sized and large companies and showing how a wide range of project requirements can be successfully implemented. Energy, Safety and Warehouse Intelligence will be further key topics in focus at the centrally located exhibition booth in Hall 10. Offering the broadest portfolio of energy and safety options for industrial trucks and leading technical material flow solutions, the intralogistics specialist supports its customers on their way to greater efficiency, sustainability and performance.

Occupying more than 500 square meters, Linde MH’s main booth in Hall 10 (Booth B21 and B17) highlights current trends in intralogistics: Automation, Energy, Safety and Warehouse Intelligence. On display will be corresponding products and solutions which are designed to optimize the internal material flow. A live demonstration will showcase flexible and scalable automation solutions involving automated guided vehicles (AGVs) and autonomous mobile robots (AMRs). Just a few meters away from the exhibition stand, in the loading yard between Halls 8 and 10, visitors can test forklifts for themselves or get an up-close look during vehicle demonstrations. Examples include various reversing assistance systems, such as the AI-based Reverse Assist Camera, that alert industrial truck drivers to people in the vicinity behind them. Additional exhibition space that offers hands-on experience with various vehicle models is located in the outdoor area between Halls 9 and 10.

“The Linde brand represents top performance in goods handling. This is achieved through innovative products and solutions, a high level of user-friendliness, a wide range of active and passive safety and assistance systems, customized individual solutions and the comprehensive consulting expertise of our sales organization. Our products and solutions ensure maximum productivity even under the most demanding operating conditions, such as those found in the beverage, paper, wood, food and chemical industries,” says Torsten Rochelmeyer, Senior Director Strategy & Solution Portfolio at Linde MH.

At LogiMAT 2024, Linde MH will showcase its expertise as a competent partner for the automation of material flow processes. “Together with our network partners, we have successfully planned and implemented hundreds of projects in recent years,” reports Rochelmeyer, referring to the sales organization’s extensive expertise and experience gained in small and large projects alike. Alongside this, standardized solution packages are available for simple transport tasks. “This allows existing brownfield processes in particular to be automated more quickly,” says the Linde trade show manager. The company’s automation experts can resort to a large product portfolio when it comes to implementing projects: The range extends from AMRs such as the Linde C-MATIC and the Linde C-MATIC HP, to automated pallet stackers (Linde L-MATIC) and tow tractors (Linde P-MATIC) all the way to reach trucks (Linde R-MATIC) and VNA trucks (Linde K-MATIC). Where complex automated material flow systems are required, colleagues from the Group’s sister company Dematic will be involved, whose booth in Hall 10 is directly adjacent to the Linde MH area.

The Energy area of the exhibition covers the company’s broad spectrum of available energy types, with a focus on the X-series electric counterbalanced trucks with lithium-ion batteries. They are just as powerful, robust and ergonomic as ICE-powered trucks, but are emission-free and potentially CO2-neutral in operation. However, diesel, LPG, CNG, lead-acid batteries, fuel cells and HVO (Hydrotreated Vegetable Oil) are also available as power options. “Visitors who want to find out about suitable energy systems for their current or future fleet will be offered software-assisted advice that provides an initial assessment based on the requirements, general conditions and customer-specific situation. This can be followed by further analysis within the company,” explains Rochelmeyer. Another focus will be on the Linde connect fleet management system. In addition to access control, damage monitoring, vehicle and driver management, fleet usage analysis and predictive maintenance, the Linde connect:charger software module provides intelligent control of battery chargers, helping to avoid expensive power peaks.

In general, the following applies to all warehouse activities: The safer the internal material flow, the higher the productivity and thus the contribution to the company’s success. Using a reach truck equipped with extensive safety features, Linde MH demonstrates how fleet operators can ensure smooth processes and protect their employees. The features range from a large number of driver assistance systems such as the Linde Safety Guard for the mutual warning of pedestrians and drivers and the Rack Protection Sensor for avoiding collisions with racks and goods to various lighting solutions and protection systems like the Dynamic Mast Control system for reducing mast vibration.

In the Warehouse Intelligence area, guests can learn how to make their warehouse even more efficient and dynamic with the help of modular software solutions. An application consisting of a warehouse management system, a forklift guidance system and a warehouse control system provides real-time visualization of the warehouse through a three-dimensional view and shows the driver the fastest route to the destination. In the process, it automatically tracks the movements of the load carriers across changing storage locations, which ensures a high degree of transparency. The software is also capable of integrating and controlling various automated systems such as AGVs and shuttles.

Sustainable Warehouse Automation Options

Posted on by David Priestman

Can warehouse automation advance sustainability? Dan Migliozzi, Head of Sales at independent systems integrator, Invar Group, looks at the options available.

Logistics and supply chain professionals are increasingly concerned about the sustainability of their operations, and in particular, about the environmental performance of their warehouses and DCs. What’s more, they have to be. Their customers are demanding ever greater and more demonstrable levels of sustainability.

This applies across the board, from how their facilities are constructed, to impacts on land use, hydrology and infrastructure requirements, transport movements generated, and of course how the facility itself is equipped and operated. As labour becomes scarcer, many businesses are considering automating warehouse processes. So, a big question for a growing number of companies is, can automation be used to advance sustainability within the warehouse?

Applied appropriately, higher levels of automation should lead to greater efficiency, less waste – including but not confined to fuel and energy – and therefore a more sustainable operation. In practice, things are not quite so clear-cut. Automation that is poorly thought out, mis-directed, inappropriately scaled, or implemented with substandard equipment, can impact both operational and environmental performance. However, a well-planned and implemented automation project can yield many sustainability benefits.

A big question is, should the automation be housed in an existing building, or is a new build designed around the requirements of automation a more sustainable solution?

A new build obviously generates a lot of carbon and uses other resources in its materials and construction. Also, a greenfield site will almost certainly impact the ‘natural’ environment, may influence drainage and groundwater and requires new infrastructure. But a new build can be designed to accommodate sustainability features such as solar panels, heat pumps, wind turbines, energy-conserving doorways, airlocks and insulation.

However, automation in an existing building may make better use of space, removing the need for physical expansion or any need to move. Exactly which option works best is a complex equation and depends on the long-term strategy of the business. Whether in a new build or refurbished premises, automation can create many other sustainability benefits beyond the walls of the shed. More accurate and timely order fulfilment can reduce the size of truck park required – fewer acres under concrete. And to the extent that headcount is reduced, that is fewer staff bringing in and parking private vehicles.

Automation can lend itself to, at least partial, ‘lights out’ operation, if appropriate, saving considerable cost and energy. Incorporating a sophisticated Building Management System which optimises the needs of manual and automated operation can yield real cost and sustainability benefits.

So, what are the sustainability issues to consider when selecting the technology? Sourcing/procurement is one area to take up with the vendor or integrator. Are machines and materials traceable to suppliers with acceptable records on their own sustainability? How much power is consumed per unit of output? Does the design of the automated system minimise the number of motors in use? Is the most energy efficient technology being considered? Could gravity be put to good use? Do control systems allow lower power consumption at times of light usage? What recharging facilities and procedures are used for Autonomous Mobile Robots (AMRs) or other electric powered vehicles?

Unpowered elements also matter. Do conveyor components have the lowest coefficient of friction? This can make a huge difference – we know an installation where low friction belts saved 65% of power consumption which, given there were seven miles of conveyor, amounted to 20% of the consumption of the whole building.

Reputable integrators and vendors should supply reliable estimates of energy consumption, related to levels of usage as part of the bidding process. They should also detail their approach to SCADA (Supervisory Control And Data Acquisition) or other approaches to monitoring energy use as part of the control system for the automation. In use, this should be able to highlight areas where power consumption is high, perhaps pointing to a need for better equipment or different modes of operation.

This approach may also uncover areas where performance is deteriorating. Vendor equipment comes with detailed Preventative Maintenance schedules for good reason – it isn’t just a ploy to ramp up spare parts sales – which, incidentally, should always be authentic parts even if they are more costly. Without proper maintenance, performance will inevitably deteriorate, and sustainability will diminish, quite possibly ending with an expensive line stoppage.

Taken all together, the potential for automation to deliver real sustainability, as well as economic gains, is clearly evident.

No Warehouse Left Behind

Posted on by David Priestman

Re-brands are sensitive and critical operations and the warehouse automation sector is no exception. David Priestman attended the launch of Movu Robotics in Belgium, late September.
“Automate, in a easy way, the distribution centres of our customers. Democratise automation.” This is the mission statement espoused by Jos de Vuyst, CEO of stow Group, at the launch of Movu Robotics, formerly known as stow Robotics. With a large existing client base for its racking, storage, silo and rack clad products stow Group is well-positioned to sell and integrate robotics and automation technology. It can scale-up fast.

The company wants to help these facilities transition to automated operations, thereby not leaving any warehouse behind in the darkening warehouses of the future. “Plug and play, dense, low-energy usage systems with fast deployment,” is the offering, according to de Vuyst. Automation provides a productivity boost and is scalable, with no need for new warehouse infrastructure.

The rationale for a new brand name – Movu – is because the ‘stow’ name is perhaps too associated with rack and storage – traditional materials handling. Disconnecting from this and switching to a ‘catchy’ new brand fits the mission statement. Employing more than 300 employees by the end of this year across Europe and the US, Movu Robotics expects order intake of more than €300 million in 2023.

The Movu Robotics portfolio comprises automated storage, picking and transport for pallets, bins and items, offering an easy buying journey, competitive pricing, cost savings, quick delivery, high density storage and space optimisation. The portfolio allows end customers and integrators globally to benefit from a seamless and user-friendly warehouse automation ecosystem.

The portfolio includes:
• ‘Movu atlas’ – Pallet shuttle for multiple deep storage
• ‘Movu ifollow’ – slimline AMR for collaborative picking or transport of pallets, made near Paris. A unique selling point of ifollow is that it works in deep freeze areas of a warehouse.
• ‘Movu escala’ – Robotised 3D storage and fulfilment system without lifts
• ‘Movu eligo’ – Integrated picking robot arm
All Movu systems are controlled and managed via their own warehouse execution software (WES).

The impressive, iconic headquarters in Lokeren, situated between Antwerp and Ghent, combines modern offices with manufacturing operations for atlas and escala robots (500 per week) under a single roof. There is also an experience centre – one of the biggest in Europe – where the latest technologies are showcased live to customers and partners. One factor in choosing its location is the desire to partner with local Universities to recruit young engineers.

I asked de Vuyst to describe the journey taken by stow Group leading to the launch of Movu Robotics:
“Since 1987 stow Group has grown rapidly into a €1 billion global company that today ranks among the top two racking manufacturers in the world. Originally a family-owned company, then owned by Kardex for a decade, a management buyout in 2013 was backed by private equity funding. The racking business of stow stands out in the sector by having a production footprint spanning Europe with 10 racking factories and a network of 20 sales companies giving direct access to, and close contact with, the customer. Our racking solutions are customised around standard products, enabling us to have highly automated factories. This results in stow being a cost leader as well as fast growing and very profitable.

“stow Robotics was born the day we started writing Warehouse Control Software (WCS). We are now developing our own WES suite and control software on the machines, which we build ourselves. We will not develop our own WMS as it is too complex. We are evolving into a supplier that can provide an automated pallet warehouse, from a small scale operation up to large projects. The investment climate is softening a bit, big investment decisions are taking a bit longer, due to high interest rates.”

Will we see ‘Dark Warehouses’ (without workers)?

“I’m a big fan in principle. The ideal is racks and robotics, but you must go high. Labour is disruptive, people often hate working in warehouses. Forklift usage is falling, as will conveyor coverage and manual picking. We have the products to achieve a dark warehouse via four or five main technologies.”

How is Movu Robotics positioned in the market?

“We expect double-digit growth. The global material handling equipment market size is forecasted to reach $350 billion by 2030, driven by AS/RS systems and robotics. By our Movu Robotics positioning and portfolio we are very confident of becoming an essential player in this market. Movu Robotics will follow the same development path as stow Racking, so we will build a network of sales companies in the main territories allowing us both channels to the market: direct and through integrators – not just to new customers, like competitors do.

“Where many companies are built around one automation product, we have an integrated ecosystem of scalable, automated warehouse solutions for pallets and bins. That’s quite rare, and the portfolio will continue to grow. We will take a deep dive into some vertical markets and develop specific automation products for particular sectors. One trend is third party logistics operators beginning to automate. We’re strong in cold stores, pharmaceuticals and food logistics.

“We want to offer the possibility of automation to SMEs that have a few thousand pallet locations. While bigger projects are generally more complex, a straight forward pallet project of, for example, 80,000 pallet locations requiring 60 shuttles has a low complexity and fits our profile. If, however, that same warehouse had sorters, a mix of complex software and machines we don’t have in our portfolio, then we’d defer to a systems integrator.” Movu does not offer robots-as-a-service as the company offers a broad range or solution.

Supermarket of Materials Handling

How do the business units in stow Group benefit from each other?

“stow Racking and Movu Robotics together are a unique one-stop-shop with proven interfaces that combines best of racking and robotics. Sales is another of the most important synergies between stow Racking and Movu Robotics, with many leads for automation coming via the racking side, which has 10,000 customers across Europe and US. Many of these customers take the decision at some point to automate their operations. stow Racking has more than 200 sales people globally, which also bring leads for robotics and automation products.

“Movu Robotics benefits from having the strength of stow Group behind it, with all of its management experience and expertise. Another important factor is the backing of Blackstone, a private equity company with a vast experience in logistic real estate, who are very supportive. Also, stow Racking activity successfully generates cash, fuelling growth in Movu Robotics without the need for continual equity rounds.”

How does the company’s culture drive development?

“While stow Group has become a large organisation, with a well organised corporate structure, it still has the dynamics of an SME company. We have direct contact with our people through a relatively flat management structure, which gives an agility and dynamism that is popular with our customers. This allows us to attract talent to support our know-how in engineering, software and other departments. Joining Movu Robotics is more akin to working in a start-up than a corporate environment. While enjoying an agile environment, staff also gain the support of being in a solid company.”

Where do you see the stow Group and Movu Robotics in five years?

“stow Group will continue to grow the racking business, we will definitely not lose interest in the racking business. Racking is an essential and profitable part of the Group, so it is important that it continues to grow. Having established stow as a racking market leader in Europe, with approx. 30% market share, we started to build the US business over the past 18 months, where there is huge potential. We have created a sales office in Chicago and have just taken the decision to build our first racking plant in the US – the location is not yet fixed. With strong sales in this market, it no longer makes practical sense to ship containers of racking across the Atlantic. We’re not excluding the Asian market later on in the future, just not now.

“Of course, we will continue to grow Movu Robotics. While entering the market with systems that are easier, standardised, scalable, and flexible, in the next five years we will be tackling more complicated projects. I think in five years’ time, Movu Robotics’ activity will be equivalent to, or even exceed, that of stow Racking, creating two very strong legs for the stow Group.”

What about further acquisitions and new products?

“Coming from a manufacturing background, doing things ourselves is in our DNA. We will develop our own technologies as much as possible, only seeking partnerships when we don’t have the time to develop them ourselves. For example, it makes no sense to start developing vision technology on our own. In such cases we will partner with an appropriate supplier or licence it in. AMRs with forks or for bins and gripping technology are interesting. The sales side is different because we want to grow as fast as possible and whilst we are developing our own sales network are open to work together if we find a good partners for specific regions.”

E-fulfilment Automation Attracts Repeat Customers

Posted on by David Priestman

What brings you back to your favourite online retailer? Other than product quality and range, it’s probably how quickly and competently they deliver your order. Consequently, the efficiency of e-fulfilment warehouses is critical for sales, as service level is a defining factor for customer retention. Automation solutions from experts such as Prime Vision provide warehouses with the tools and data that increase the accuracy and speed of order fulfilment, leading to enhanced customer satisfaction and repeat orders in the future.

Order, receive, repeat

An intuitive, attractive e-commerce platform with a good range of products is highly effective at catching potential customers’ attention. However, beyond initial exposure, holding onto them relies not only on the product meeting expectation but also on the service that follows the payment. A long delivery time, or a late arrival, will often push a consumer to another retailer that can do it faster. Shipping the wrong item means an unhappy shopper too, along with a costly return. All result in lost revenue and potentially, damaged reputation.

Customer retention is essential for the long-term viability of any business and is dependent on fostering loyalty and trust. It’s no secret that attracting a new customer is usually more expensive than retaining an existing one. Performing poorly at the dispatch and delivery stage will most likely result in a one-off order. Customer lifetime value (CLV) to the retailer would be equal to that single purchase and, considering customer acquisition costs linked to marketing and sales, the return on investment (ROI) could be disappointing – especially if that one order is returned.
Repeat customers are more lucrative, so retaining them is a top priority, and e-fulfilment operations must function effectively to keep consumers coming back.

Meeting service expectations with automation

Today, an efficient fulfilment operation is an automated one, and there is a wide range of smart automation solutions available that can raise service level and ensure customer orders are more than a one-time deal.

For example, automatic storage and retrieval systems paired with Prime Vision mobile autonomous robots (AMRs) and computer vision systems allow items to move faster through the warehouse. As a result, parcels containing orders are sorted quicker, reducing overall delivery times and the risk of a customer choosing another retailer with a shorter lead time.

This is achieved while improving accuracy. Inventory management systems, analytics software and computer vision provide full traceability across the warehouse. Operators can therefore usually identify errors before an item is dispatched, minimising returns and boosting customer satisfaction. Additionally, bottlenecks in warehouse sorting processes can be identified and resolved, further promoting efficiency.

Automation in peak demand

Automated operations are exceptionally proficient at catering for periods of high demand too – like Black Friday or Cyber Monday. An overwhelmed logistics operation results in delayed deliveries that can scare shoppers away. On the other hand, offering a consistent service level during these peak times is highly profitable. The latter is no easy task with current labour shortages in the sector. Thankfully software, robots and computer vision systems are very scalable. This means businesses can achieve higher warehouse throughput with limited resources, ensuring that existing staff aren’t overworked during peak periods.

Solutions such as Prime Vision’s Flow Projectors remove mind-numbing, time intensive tasks such as label reading, instead projecting a number that corresponds to a destination or chute on each parcel. Therefore, workers find sorting faster and easier. With these twin benefits, automation enables high demand to be met sustainably, protecting the existing workforce and safeguarding customer loyalty.

Data and discerning buyer behaviour

Gathering sales, warehouse stock inventory and other customer relationship management (CRM) data also empowers businesses to enact a feed-forward approach that can predict and influence customer behaviour. Working out buying habits means e-commerce platforms can use cross-selling or ‘frequently bought together’ features, encouraging shoppers to order more. For consumable products that are purchased repeatedly, the platform can suggest setting up a subscription.

On the fulfilment side, access to historical warehouse CRM data also allows buyer behaviours to be identified, so businesses can tailor their inventory management to capitalise. Bespoke analytics software backed by expert consultation focusing on particular areas of the fulfilment process are solutions Prime Vision has offered to its customers for leaner warehouse management.

Such an approach allows warehouses to optimise inventory volumes and individual product locations by actioning findings on what sells when and where, like surfboards in summer or by the coast. Businesses can then ensure availability for seasonally popular products and reduce delivery times by holding them locally. Often-paired items can even be stored in close proximity within the fulfilment facility itself. Once the data is gathered and analysed, the results can be a true eye-opener and, by addressing even a minor issue, a smoother, more efficient operation and time-saving practices can be established.

Get e-fulfilment right first time

In the experience of Prime Vision, automating e-commerce logistics can positively impact sales. The ability of automation to improve the efficiency of every aspect of a warehouse operation means faster delivery and reduced errors, enhancing customer service and fostering loyalty. Scalability ensures that this service level stays consistent even during peak times, protecting staff from burnout and maximising profitability at key moments. Using data to analyse and predict buyer behaviour can be used to enhance fulfilment operations, translating into high value, repeat purchases thanks to order accuracy and the speedy service received by customers.

Arvato opens Hamm DC

Posted on by David Priestman

Arvato and Douglas, a European omnichannel provider for beauty, have jointly officially opened their new location in Hamm, Germany. The new distribution centre with its state-of-the-art automation technology is a lighthouse project for both companies and marks the next step in their long-standing partnership. With a total area of 38,000 sq m, Arvato will handle all logistics for store deliveries and Douglas’ fast-growing online business in the DACH region – including returns management. The new logistics centre will create up to 400 jobs in Hamm.

After commissioning the logistics centre in August last year, Arvato initially began processing orders for online customers in Germany, Austria and Switzerland. In the meantime, all Douglas stores in the DACH region are also supplied from Hamm.

With the new logistics centre, Arvato has tripled warehouse capacity for Europe’s leading omnichannel beauty provider, whose online sales have grown by an average of more than 20% per year over the past five years.

“We have created a forward-looking concept in Hamm that optimally supports not only growth but also the Douglas ‘Let it Bloom’ strategy,” said Julia Börs, President Consumer Products at Arvato, underlining the importance of the project.

“Efficient logistics is one of the most important pillars for any omnichannel retailer. With the new and state-of-the-art logistics centre in Hamm, we have reached a decisive milestone in linking store business and online store in the DACH region even more closely – also and especially to the benefit of our customers and suppliers,” said Sander van der Laan, CEO of the Douglas Group.

Arvato’s digitisation strategy perfectly supports Douglas’ cross-channel business model. The supply chain and e-commerce service provider has specifically designed the DC in Hamm as an omnichannel warehouse with high-performance automation technology and a cloud-based IT solution, in which Douglas’ various sales channels and country orders are brought together.

At the heart of the omnichannel solution is a state-of-the-art shuttle system from Austrian supplier KNAPP, with whom Arvato has been working for many years. The system of the latest 2D generation (OSR Shuttle Evo) has more than 130,000 storage locations, 32 ergonomic workstations and a storage and retrieval capacity of 12,500 totes per hour. At the same time, the more than 500 shuttles can not only move within an aisle, but also change aisles if necessary, thus reaching all items on one level.

This increases flexibility enormously and reduces the effort required for conveyor technology outside the shuttles. The shuttle is part of a sophisticated overall system which, with the connected automatic carton and tote erectors, three cross-belt sorters, pick-by-light picking stations for samples and large-volume items, and automatic carton sealing machines, interlocks perfectly.

Subsequent sorting then takes place in the goods issue and dispatch departments.

Börs said: “In total, we have invested more than €70m in state-of-the-art automation technologies at the Hamm site. This is the largest investment in a single site to date.”

In full operation, up to 114,000 packages per day can be shipped from Hamm. Fast delivery to customers in the DACH region is supported by the very good location of the DC in the eastern Ruhr region and the connection to several highways. “The location is also fundamentally equipped for further growth, as together with Douglas we already took into account possible capacity expansions in various functional areas during the design phase,” explained Börs.

Automotive Supply Chains not Sustainable

Posted on by David Priestman

According to the latest report The automotive supply chain: Pursuing long-term resilience from the Capgemini Research Institute, automotive organisations now feel more confident to tackle future supply chain disruptions. To achieve this, automakers have been forced to rethink, restructure, and refinance their supply chain management. While issues have been stabilised in the short-term, supply chains are still transforming due to their complexity and evolving factors: the acceleration of electric vehicle (EV) production, the new regulatory and government policies, and the adoption of more software-based features like ADAS (Advanced Driver Assistance Systems), increasing the demand for semiconductors.

A global re-orchestration is underway as procurement from offshore locations fell by 22% in the past two years. Europe leads this trend having reduced offshore procurement by a quarter since 2021. This is followed by APAC and the US who have reduced offshore sourcing by 20% and 18% respectively.

The report finds that automotive organisations expect procurement from offshoring locations to reduce by a further 19% by 2025, as electric vehicle production surges and the fabrication of key electronics components relocates.

Sustainability Efforts are Faltering

Successive supply chain crises have sapped automakers’ time and diverted focus and investment away from sustainability initiatives. Consequently, sustainability is not currently considered a priority for many of them, with only 37% of respondents stating that issues such as carbon footprint management and environmental risk influence supply chain decision-making. Investment across the industry reflects this trend and while OEMs’ total investment in supply chain sustainability is on par with last year, suppliers’ annual investment has significantly reduced by 17%.

While sustainability and circularity are key components for building a more resilient supply chain and to future-proof operations, the scaling of circular-economy initiatives has been delayed due to a shortage of suppliers of recycled materials (and of the materials themselves).

Automotive organisations need to balance sustainability and circular economy with factors like cost and affordability. According to the report, digital solutions can help address this delicate balance between these various competing factors.

Accelerate of Nearshoring

Driven by a surge in efforts to deliver software-based features and services, the average proportion of vehicle value attributed to semiconductors and sensors increased by 51% over the last two years. This is expected to increase by a further 46% between 2023 and 2025.

However, only half of OEMs consider the current supply of semiconductor components as secure. Of those surveyed, 70% said the majority of supply is currently being obtained from China, Taiwan, Japan, and Korea. In a bid to achieve a greater level of supply-security OEMs are investing in alternative supply methods and moving away from tier-1 and -2 suppliers. Similarly, OEMs have secured only three years of EV battery raw materials on average.

Inventory Building not Feasible in Long-Term

According to the report, half of OEMs feel confident that they would be able to avoid 60% of the revenue loss they incurred in 2022 if the same scenarios – including the semiconductor shortage – happened again today.

To address operational and logistic issues, both suppliers and OEMs have adopted strategies based on adding operational investment and working capital. This is led by the building of inventories, which 81% of suppliers and 44% of OEMs have implemented. However, it’s clear that this is unsustainable in the long-term as holding excessive inventory risks a variety of negative effects on the operational and financial wellbeing of automotive organisations.

Lack of Data-Driven Intelligent Supply Chains

Visibility and transparency are key to create a more trustworthy supplier ecosystem – just over half (53%) of respondents have a mature intelligent supply chain in place to enable data-driven decision making, allowing for the integration of newer technologies such as AI and data analytics. With growing participation in standardised, open, and trusted data ecosystems that include new suppliers for software driven services, automotive organisations can further progress resilience and sustainability ambitions.

Alexandre Audoin, Global Head of Automotive Industry at Capgemini, comments: “Over the past few years, organisations have been forced to restructure and refinance supply chain management on the fly in order to navigate multiple disruptions from all fronts. While in a more positive place today, automakers need to look at delivering a long-term, intelligent, and data-driven strategy that will build resilience and competitive advantage. More so, this needs to incorporate circularity as an essential component, not only to help organisations navigate regulatory changes, but to embed new players in the supply chain ecosystem and also achieve ambitious climate-targets.”

CLICK HERE to download the report.

 

 

Dexory partners with Linkline

Posted on by David Priestman

Dexory has partnered with Northamptonshire warehousing and logistics 3PL Linkline to unlock operational efficiencies using real-time data at its warehouse in Kettering, with a view to further roll-out to the wider estate.

Linkline already uses various automation solutions, and plans on building a large, automated hub in 12–18 months’ time to support its growth plans and ambition to drive greater efficiencies for its customers. This drive and innovative approach further demonstrates a commitment to invest in technology, making this an ideal partnership for Dexory.

Dexory’s solution addresses the urgent need for improved space utilisation and increased efficiencies, combining powerful analytics with autonomous robots capable of capturing rich image and sensor data from across any warehouse. This powerful combination provides comprehensive and actionable visibility across warehouses of any size, as well as connecting warehouses across the global supply chain through Dexory’s digital platform, DexoryView.

Linkline aims to introduce its data collection autonomous robot Dextor (the name the Linkline team have given the robot) to the Kettering site next week (w/c 11th September). Dextor will then operate every night, scanning the full 250,000 sq ft warehouse, integrating into the day to day warehouse operations, working alongside the operations and warehouse teams. Progress can be followed on the Linkline Transport LinkedIn page during this first week.

James Bowes, Chairman of Linkline, commented: “We’re hugely excited to start putting Dextor to use in our warehouses. We’re always looking at technological solutions to drive more value for our customers and Dextor will do just that. We anticipate strong time savings for our warehouse operators who currently have to manually stock check at regular intervals throughout the week whereas now this process will be completed at night by Dextor.”

Oana Jinga, Chief Commercial Officer & Co-founder of Dexory, added: “Dexory is really excited to have Linkline on board and really seeing the value of data-driven technology for their operations. Integrating DexoryView into their Kettering warehouse, will allow them to unlock greater efficiencies and proactively prevent any errors resulting from stock inaccuracy, delivering on the best point of service for both themselves and their customers.”

Why FMCG Supply Chains are about Balance

Posted on by David Priestman

FMCG Supply Chains are delicate things, writes Tim Bruun (pictured), Head of Customer Management – Retail & FMCG at Transporeon.

Transporting day to day goods like food and toiletries has always come with challenges and pressures and having items that are daily necessities for millions of people around the world and must be available at all times is a given. I’m sure we all remember the drama when toilet roll shortages swept across Europe during the height of the pandemic.

However, when analysing the current state of the market, we can see two distinct trends. On the one hand, the market is softening and the capacity crunch is reducing after tightening in 2021 and the first half of 2022. Indeed, the future prognosis for the global FMCG market is generally positive. It is predicted to grow by €284.4 billion by 2026, largely due to the growing preference for eCommerce online distribution.

However, at the same time, impending recession and rising inflation is causing production demand to drop and prices to rise. Consumer goods companies are now dealing with billions in additional costs, thanks to rising prices for raw materials and transportation. These are generally higher for FMCG products, due to specific temperature and humidity requirements.

This is likely to continue throughout 2023. But, the big question is, what does it all mean for businesses in terms of driving future growth and success?

In the balance

With these trends in mind, FMCG businesses are facing a delicate balancing act of keeping costs down while meeting the needs of increasingly demanding consumers who have considerable purchasing power. An empty shelf isn’t just a lost sale for someone – it’s a reason for customers to switch to another brand.

Those involved in FMCG supply chains are also looking to drive as much value as possible from their operations yet ensure resilience against disruptions that, according to McKinsey, are becoming ever more frequent. How well FMCG suppliers achieve this balance will determine their success in 2023 and beyond.

Achieving an equilibrium between value and resilience starts with digitisation. The truth is that FMCG logistics aren’t as digitised as they should be. They still rely on plenty of paper-based processes that cause inefficiencies. The good news is there’s a drive within the industry to replace them with e-documents and digital processes.

Additional value can also be realised by implementing automation to save time on elements such as time slot and yard management processes. As a result, FMCG businesses will be able to streamline and enhance their tactical activities, which is crucial since millions of people worldwide depend on FMCG supply chains every day, as well as the time-sensitive storage and consumption windows for many perishable products – some of which are only available for a short period of time.

Embracing a digital-first mindset will empower FMCG businesses to deliver the speed and convenience that consumers are looking for, while optimising their operations and building greater profit margins. At the same time, it will provide resilience by making it easier to adapt to disruption. A lack of resilience can be fatal for modern FMCG brands, but achieving it requires businesses to think beyond basic automation by focusing on data and relationships.

Realising FMCG 2.0

The only way FMCG businesses can truly ensure resilience is by enhancing their ability to execute on market and operational insights. This is what will enable them to react to fluctuating customer demands and adapt to unforeseen events such as border closures or dangerous weather conditions. With the right data at their fingertips, businesses will be able to make more data informed decisions in a timely fashion – relying on actionable insights rather than gut feel – and build optionality into their operations.

At the same time, tapping into data is what will provide balance in terms of optimising their operations. Consider a day to day product such as toilet rolls which is transported from warehouses to multiple countries and hundreds – if not thousands – of locations within those countries on a near-daily basis. These transports may have to cross international borders, adapt their routes due to traffic jams or road closures, and sync up with countless other transports. The logistics involved are staggering, but data can act as the common thread that ties such a complex operation together.

In order to succeed, businesses within the FMCG supply chain must be prepared to build deeper relationships and drive collaboration with other industry stakeholders within one connected network. They must work together to realise the economic gains available. For example, there’s no need for a truck to drive hundreds of empty miles to pick up a load when another may be unloading nearby.

A deeper collaboration through a common platform can provide the balance that is essential – whether that’s by increasing resiliency, providing wider access to market data, reducing costs, or enabling more sustainable supply chains.

Ultimately, the goal of any FMCG stakeholder is to ensure that products make it to customers on time, every time. The key is to maintain the flow of goods, no matter what challenges come their way. And, like any ecosystem, the world of FMCG transportation is all about balance. Taking a digital-first approach driven by data and relationships will help FMCG businesses balance their operations in a way that drives sustained success.

IFOY Test Report: Airrob by Libiao

Posted on by David Priestman

As we move inexorably towards the moment when the IFOY Awards are handed out in Dortmund on June 22nd, we continue our look at all of the 2023 finalists and share the verdict from the IFOY test conducted during the evaluation by an expert jury in March. Our next entry is the Airrob container handling robotic system from Zhejiang Libiao Robots Co., Ltd.

Zhejiang Libiao Robots invented the world’s first sortation robots five years ago; now they have created another new robotic system named Airrob container handling robotic system. The robots can climb racks, and store, pick, sort, and move plastic containers, and the climbing robot can move vertical and horizontal direction freely. It is a simple, efficient and flexible system for the fulfilment centre or the work-line-side storage system.

Category: Intralogistics Robot

IFOY Test Report

Libiao Robotics has been nominated for an IFOY AWARD with its Airrob, a “climbing” container robot. Its maximum load capacity is 25kg.

The system is suitable for the vast majority of all containers in this weight class, about 95% according to the manufacturer, and virtually all racks. It allows a quick and easy installation, even when retrofitting existing warehouses. Adjustments to the floor are not required. However, horizontal rails must be attached to the rack, over which the Airrob travels along the rack. The maximum speed of the robot is 2m/s.

The Airrob is attached to a lightweight frame that moves along the horizontal rails through the aisle. This design allows the robot to “climb” up the shelves and store or retrieve the correct container on the shelf at any desired location. Each bin is thus directly accessible at all times.

The frame is flexible and automatically adjusts to the position of the robot. This ensures high reliability and fast, trouble-free and stable transport of the boxes.

The system is suitable for racks up to 12m high. In this case, however, Libiao mounts two Airrobs on top of each other, as this requires less adjustment.

A unique feature is the hook system used to move the crates in and out of the racks. The hook moves within the contours of the robot, which does not penetrate the shelves. This allows the boxes to be stored extremely compact. The hook system is suitable for handling totes on both sides of an aisle. This limits the aisle width to about 85cm.

The concept is lighter than a miniload, a multishuttle or an autonomous case robot (ACR). This is one of the reasons why energy consumption is low. Consumption could not be measured by the IFOY test team, but according to the manufacturer, the savings compared to competing solutions is more than 30%.

The battery built into the Airrob is maintenance-free and is charged when the tablet is switched on and off; according to the non-sliding touch charging principle. The rack on which the Airrob is mounted is powered by mains electricity.

In the Pick&Go setups during IFOY TEST DAYS, the Airrob worked with the manufacturer’s AMRs, but other configurations are also conceivable.

The concept is particularly suitable for micro-fulfilment centres and can also be used in ambient temperatures as low as -20°C, for example in cold stores.

IFOY test verdict: The Libiao Airrob container handling system can set a new standard for mobile robots and fundamentally change existing solutions. The Airrob is cost-effective, scalable, and efficient. The system saves space and labour. The unique hook system guarantees high storage density.

IFOY Innovation Check

Market relevance: The Airrob solution addresses manually operated warehouses that are to be automated cost-effectively using existing racking infrastructure and potentially inhomogeneous container systems. With an ROI of one to two years for the 10 installations currently on the market, the Airrob system is an attractive option for brownfield automation in diverse industries such as warehouse logistics, e-commerce, or manufacturing. Airrob can be used for rack heights between approx. 2m and 14m and is already economical in smaller warehouses starting at 100 sq m. The market potential is high due to the high flexibility of the system, the comparably low costs, the wide range of applications as well as worldwide marketing partners.

Customer benefit: The greatest benefit of Airrob is its flexibility and adaptability for use in existing warehouses without replacing existing infrastructure. This also results in manageable investment costs, which should be a fraction of fully automated systems. Set-up and commissioning are in the range of one to four weeks. Due to the modularity, additional robots can be temporarily integrated for more throughput at peak times. Compared to similar solutions on the market, Airrob is said to consume 30% less energy. In addition, the system is easily reusable in other operating environments.

Novelty / Innovation: Airrob stands out for its simplicity of design, which enables high efficiency and robustness at low cost. Nevertheless, several innovative details have been implemented for the applicability in a wide range of manually operated warehouses. The vertical guide is flexibly mounted on two horizontal rails on the rack, so that even inclined shelves can be approached with the appropriate inclination. A simple hook mechanism allows access to various standard containers from two parallel shelves. Unlike comparable solutions, a fast-charging mechanism ensures 24/7 operation of the pick robot, so fewer pick robots are needed overall.

Functionality / Type of implementation: The pick robot, a type of stacker crane, is designed to be simple and practical, enabling a rapid access time of about 30 seconds to the totes weighing up to 25kg. The throughput of containers can be scaled flexibly by dividing the tasks between the pick robot on the rack and the mobile transport robots. With a temperature range between -20°C and 50°C, freezer applications are also possible.

Verdict: With Airrob, existing rack storage systems for any standard containers can be automated very cost-effectively. The easily retrofittable and technically minimalist solution for removing totes from heights of up to 14m, in conjunction with a fleet of mobile transport robots, enables significant efficiency gains compared to manual warehouse management. Technical highlights include the simple but universal gripper for crate removal and return, adaptivity to typical real-world conditions such as sloping shelf layers, and a fast-charging function for 24/7 operation.

Market relevance ++
Customer benefit ++
Novelty / Innovation +
Functionality / Type of implementation ++
[KEY: ++ very good / + good / Ø balanced / – less / — not available]

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