ECOM FULFILMENT CENTER - WAREHOUSE AUTOMATION TRENDS - TECHNOLOGIES

1. FULFILMENT CENTER
AUTOMATION –TRENDS AND
TECHNOLOGIES

2. FC AUTOMATION
Automation is the application of automated machinery and computer software to improve the efficiency of FC
operations. Typically this refers to operations within a warehouse or distribution center, with broader tasks
undertaken by supply chain management systems and enterprise resource planning systems
During the Distribution Process, Products pass through a number of steps as below:
Receiving & QA Checks
Put‐Away / Storage
Order Picking
Repacking
Shipping
Logistics automation systems can powerfully complement the facilities provided by these higher level computer
systems. The focus is shifting from a WCS interfaces with a WMS to an Integrated WES to build in all
requirements into a single platform

3. WHY AUTOMATION?
 80% of warehouse Building costs are in the floor slab and roof. Automation will help reduce these and hence
help in optimizing building costs. Reduction will also help address scarcity of affordable warehouse space.
 In traditional rack storage systems 60% of the space is aisles, In FCs, this is typically 66% and automation
will help address this by reducing Aisle Space
 A large part of total Cost of Service referred to as CPS (often >60%) is related to Order Picking which
impacts operational costs related to increasingly high customer service levels and cost of retaining skilled/
qualified staff can be optimized by Automation
 By reducing manpower dependency, Automation can address Business Continuity Risks related to labor
issues
 Automation can also address aspects related to health, safety and ergonomics regulations
 Automation will also provide a scalable design (using vertical space) so that the longevity of the facility is
enhanced
 To summarize, industry data indicates that adoption of warehouse automation is continuing to grow, the main
reasons are associated with growth, cost and service.

4. Flow Diagram
Inbound Conveyor
Automation
Telescopic Powered
Conveyors/Flexible Conveyors/Open
truck Robotic Unloading System
Cartons/Plastic Bags/
Pallets
Receiving & Segregation
Book Shrink wrapping Automation
& Case profile Automation
Trash
Conveyor for
Dunnage
Automated conveyor system
& auto sorting system with Auto
WID Application System
Receiving and Segregation are labor intensive operations; Automation can help reduce both handling and system
footprint. Options available are as below:
 Unloading Automation at Docks (also applicable to Loading) – Flexible Conveyor( Power/Gravity), Telescopic
Boom Conveyors
 Segregation & ID labeling (WID) – Automated Batch process conveyor, WID Pasting with Sorting Conveyor
 Shrink Wrapping Automation with integrated conveyors – Pre-packing applicable to Books
RECEIVING & SEGREGATION
AUTOMATION

5. AUTOMATED DOCK LOADING AND UNLOADING
Benefits of Automated Dock Loading and Unloading System:
Automated systems in dock loading and unloading can improve productivity in loading or unloading of trucks and trailers.
Automated dock equipment can be improved by linking two systems: the Conveyor accessing the truck/trailer and a
system inside the facility to carry material directly to process stations. When the truck/trailer is positioned at the dock, the
entire load can be moved with minimal human effort (almost automatically). Reduces loading /unloading time by up to
70% in non-palletized operations (as in e-Commerce); Reduction of Human Effort/Movement. Optimizes / reduces labor
costs and Improves workplace safety
Conclusion:
1. Telescopic Boom conveyor is used for cartons (odd sizes also can be accommodated) or other material < 12kg
(capacity up to 30kg). Cantilever boom extension (7m) from Dock into the truck improves operations as there is no
dependency on floor or truck base level or undulations (quality). World Class Solution with High Productivity @ Cost
~25L INR.
2. Collapsible flexible conveyor with powered or gravity operation can handle cartons and other packages up to 10 kg,
but cannot handle odd shaped bags. Skate wheels can replace rollers. Manual intervention in positioning/moving of
conveyor. Limited improvement in Productivity (~50%) combined with dependency on floor quality @ Cost ~8L INR
(powered) and 3L (gravity)
3. Gantry / Cartesian Robots can be deployed for unloading of Standard Size Cartons. Preferred for higher Weight Limit
of 30 Kg and above. May not suitable for E-Commerce.

6. AUTOMATED DOCK LOADING
AND UNLOADING - IMAGES

7. PUT-AWAY, STORAGE,
PICKING
Put-Away, Storage & Order Picking are key processes in an FC following Receiving & Segregation Process. This
process involves Storage of material SKU wise in multiple locations. Semi-automated options will involve manual Put-
away & Storage assisted by HHD’s with Barcode label location identifications. Fully automated options will involve ASRS
equipment with typical Goods-to-man operations using automation Technologies.
Oder Picking happen w.r.t customer order. Customer order to be picked from inventory using manual method using
HHD’s or can be Fully or Semi-Automated using Modern Trend of automation Technologies.
Mezzanine Shelf Storage
(G/G1/G2/G3) OR
Storage Automation
Put-away Conveyor System
Put-To-Light System/Mini-load
ASRS/Auto Store/Perfect Pick/Ibot
System
Picking System
Pick-To-Light System/Mini-load
ASRS/Auto Store/Perfect
Pick/Ibot System
Tote Transfer Conveyor Automation
Tote Sorting System
Spiral Conveyor System/Sorting
Wheel divert/Barcode/90 Degree
Transfer/Shoe Sorter
NDD/SDD/Normal/Packaging
Based(Carton/Poly Bag)
Empty Tote Storage
Automation

8. PUT-AWAY, STORAGE, PICKING
AUTOMATION
Put-Away, Storage & Order picking methods are divided into Automated & Semi-Automated Technologies
Automated Technologies:
Mini-load ASRS with Integrated Goods-To-Man Conveyor
Vertical Deeplane Tote ASRS with Integrated Goods-To-Man (Trade Name – Autostore)
High Speed Multi-Shuttle/I-Bot with Integrated Goods-To-Man (Trade Name – Perfect Pick)
High-Speed Multi Level Shuttle ASRS with Integrated Goods-To-Man (Trade Names - RapidStore, Power Store,
Automha)
Auto-Guided Butler / Kiva Robots with Integrated Goods-To-Man System (Trade Names – Amazon Kiva, Swisslog )
Semi-Automated Technologies:
Mezzanine Shelves with Put-Away & Picking Tote Conveyor system using HHD Scanner Picking/Putting
Put-To-Light & Pick-To-Light System
Conclusion:
1. Picking & Putting Manual with Shelf racking system can be semi-automated with Put-To-Light, Put-To-Light System & Tote
Handling Conveyors. Minimum Throughput should be 8,000 Shipments/Hrs for better ROI.
2. Semi-Automated automation reduces 20% of manpower, high productivity.
3. Integrated system Storage Automation Goods-To-Man its depends upon the throughput. Minimum Throughput should be
20,000 Shipments/Hrs for good ROI.
4. Integrated system Storage Automation Goods-To-Man reduces 80% in manpower & handling damages with increase of
productivity

9. Semi-Automated Technologies:
Automated Technologies:
Put-Away, Storage & Order Picking –
Images

10. PACKING AUTOMATION
Packaging automation systems seamlessly integrate an array of automated packaging subsystems and tasks into one
cohesive, highly optimized, highly accurate packaging automation operation. An automated packaging system that
ensures the right item gets to the right person in the right package in a manner consistent with your company’s brand
standards — every time.
FC Packaging automation are divided in to Carton & Poly Bag Packaging automation.
Packed Goods
Automated Packing System with Auto
Destination Barcode Pasting/Stand
alone Air Pouch Fill Machine
Carton/Poly Bag
Empty Tote Transfer
Conveyor
Flow Diagram
Conclusion:
1. Polybag Packing - Standard packing dimensions are important. Required before middle level of sorter to sort size
wise shipments to choose polybag packing Machine. Throughput of the machine – 700 Shipments/Hr. Can replace
entire Table Packing Systems with Accessories like Label Printer & Applicator. Can Save 90% of Manpower.
2. Carton Packing Equipment integrates Conveyors, Carton Erectors, Label Applicators, Invoice Printers, etc. Can Save
90% of Manpower. Integrated systems can handle ~ 6K to 20K Shipments/Hr. Standard packing dimensions of
Package Required. Output from size wise segments will be fed to Sorters for final sorting.
Filled Totes
To Sorter

11. Carton Packing Automation
Autobag Packing Automation
PACKING AUTOMATION - IMAGES

12. SORTING AUTOMATION
Sortation can be a semi-automated or a fully-automated process.
A sortation system identifies products and/or packages (i.e. entities) and in turn transports, merges, inducts, separates,
sorts, routes and/or consolidates these entities to specified destinations as per the requirements of the distribution
operation
Scanner/Profiler/Weigh Sortation TechnologiesCarton/Poly Bag
Flow Diagram

13. SORTING DESIGN BASIS

14. Sortation System Flow Diagram

15. Sortation System Types

16. DEFLECTOR/SWING ARM SORTER
A deflector is a mechanical device that will redirect an item off a belt conveyor onto an “after sort” lane.
The deflector arm normally has a low friction static face. Deflectors are typically best applied for a small
number of diverts at a low rate. Items to be deflected must be capable of withstanding the impact of the
deflector.
Typical Applications & Limitations:
•Generally applied to low throughput applications
•Max. Throughput – 40 Products/Min
•System Handle only Cartons/Polybags/Pouch’s
•If Plastic Chain Conveyor Bed, System makes Lot of Noise(Falling short of Industry Standards)
•Limited through put / Volume Rate. Cannot handle smaller Dimension Products
•Higher speed pusher diverters can have a high impact on the product being sorted
•Less Investment in Cost

17. ORTHOGONAL SORTER
 Powered roller conveyor with 90°bi-directional package transfer to left or right
 Pneumatic / Cam lift is used to divert package
 Standard diverter with pop-up straps has a lower sortation rate of 25 -30 cartons sorted
per minute (~150 Items/Min in typical B2B)
 High Speed diverter with pop-up rollers can sort up to 40 -60 cartons per minute
 Requires a flat-bottom entity such as a carton or tote
Typical Applications & Limitations:
 Product Dimensions are Limited
 Merge batch picked items to a highway lane
 Cannot operate without Cartons/Totes
 Medium throughput sortation to shipping lanes

18. STRIP BELT SORTER
 Bi-directional right angle transfers
 Motorized pulley drive with pneumatic transfer lift for orthogonal transfers
 Designed to sort parcels up to 100 Lbs at speeds of 25 -65 items/cartons/totes per minute
 Used to sort totes
Typical Applications & Limitations:
 Suitable for totes & trays
 Highly energy efficient
 Product weight constraint
 Medium Cost

19. WHEEL DIVERTER SORTER
 Pneumatic rotary actuator turns wheels for diverting cartons 30°to left or right
 Wheels rotate or pop up to divert Package or Totes
 Steerable wheel diverter can sort 30 -80 items per minute
Typical Applications & Limitations:
 Steerable wheel handles min. carton dimensions
 Pop-up wheel handles minimum carton dimensions
 Flexible and modular diverter that can easily be relocated within a conveyor system
 Wide Range of throughput rates supported

20. LINEAR SHOE SORTER
Shoe sortation provides a very soft, positive divert at rates up to 220 cartons per minute. Shoe sorters
can be used in applications where there is a wide variety of product sizes, shapes and weights being
sorted. It is an excellent sortation choice when the product is fragile or easily damaged and requires a
smooth and gentle movement from the sorter to the takeaway lane.
Large distance between sorts means the solution is not space efficient.
Shoe sorter Type:
1. Linear Sliding Shoe Bi-Directional Divert - 150 –380 cartons per minute
2. Linear Sliding Shoe Sorter Angle Divert: - 100 -280 cartons per minute throughput capacity

21. CAROUSEL SORT – TILT TRAY
 High-speed chain-driven 2-way sorter used for a wide mix of unit or parcel sortation
 Wide choice of induction units and chute designs
 Flexibility to scale down throughput speed to reduce product impact
 Speed can range 100 –150 m/min
 Can sort 23,000 -25,000+ pieces per hour depending on design
Typical Applications & Limitations:
 Applied where a diverse range of units or parcels are sorted to destination chutes/lanes.
 Commonly used to sort a wide range of products including apparel, small items in poly bags, mail
envelopes, courier parcels DVD’s, CD’s and small to large corrugated boxes.
 High-accuracy, high-speed, low-noise system that is scalable
 Modular by design –flexible to change, wide range of sizes
 Action is not positive and slips can lead to items not sorted

22. CAROUSEL – CROSS BELT SORTER
 High-speed bi-directional sorter diverts items or cartons 90°left or right with true positive sortation
 Divert points can be at close intervals for space efficiency
 Single, twin, double deck and quad cell
 Can sort 12,000 -18,000+ pieces per hour depending on design
Typical Applications & Limitations:
 High speed throughput applications that can handles minimum item dimensions
 Diverts units or cartons to destination lanes
 Flexible and modular diverter that can easily be relocated within a conveyor system
 Flexibility to sort a wide range of entities of their shape, size and surface characteristics
 High cost system

23. CAROUSEL SORT – BOMB-BAY
 High-speed continuous loop sorter that is typically an oval race track traveling at ~140 m/minute
 8 operators can manually induct up to 40,000 pieces/hr at 2 ends of the loop
 Also known as a split tray or quad tray sorter because trays can be divided into 2 or 4 sub-trays
Typical Applications & Limitations:
 Often used to sort apparel / soft goods or small products that can fit on a tray and that are not fragile.
 High-accuracy, high-speed sortation that can scale to low throughput applications
 Less space requirement because chutes can be directly below the sorter
 Efficiency constraints when 4 people induct at one induction station
 Each wave release requires time to reset the shipping cartons under the sorter

24. SELECTION GUIDELINES OF SORTERS

25. Outbound automation:
Post sorting and Destination hub Bagging, Outbound dock can be automated by using Dock Equipment. `
Outbound AutomationAGV’s/Conveyor AutomationPlastic Bags
Flow Diagram
Conclusion:
1. Similar to Inbound Equipment. Telescopic belt unloader is suitable of FC Load/Unload Dock operation.
This can handle any odd bags also. We can reduce 70% of unloading time and required minimum
Manpower for the operations. Handling Load limit to Max. 50 Kgs/Mrt. Cost of Equipment – 25L Base
Price.
OUTBOUND AUTOMATION

26. Outbound automation:
Post sorting and Destination hub Bagging, Outbound dock can be automated by using Dock Equipment. `
Outbound AutomationAGV’s/Conveyor AutomationPlastic Bags
Flow Diagram
Conclusion:
1. Similar to Inbound Equipment. Telescopic belt unloader is suitable of FC Load/Unload Dock operation.
This can handle any odd bags also. We can reduce 70% of unloading time and required minimum
Manpower for the operations. Handling Load limit to Max. 50 Kgs/Mrt. Cost of Equipment – 25L Base
Price.
OUTBOUND AUTOMATION

27. QA SESSION..
CONTACT– NANDISH SM
EMAIL:nandime@gmail.com