April 20 2022

What is warehouse automation?

Warehouse Automation

What is warehouse automation?

Warehouse automation is the process of automating the movement of inventory into, within, and out of warehouses to customers with minimal human assistance. As part of an automation project, a business can eliminate labor-intensive duties that involve repetitive physical work and manual data entry and analysis.

For example, a warehouse worker may load an autonomous mobile robot with heavy packages. The robot moves the inventory from one end of the warehouse to the shipping zone and software records the movement of that inventory, keeping all records current. These robots improve the efficiency, speed, reliability and accuracy of this task.

But warehouse automation does not require physical or robotic automation, and in many cases simply refers to the use of software to replace manual tasks. However, this scenario illustrates how robots and humans work together to accomplish repetitive tasks while minimizing fatigue and injury.

Our mission

Automating global warehouses

How does warehouse automation work?

Due to the rapid advances in technology nowadays, software and technology are able to fully automate logistics processes through robotics or sensors. Caja Robotics’ flexible solutions ensure that business-critical-tasks in customer facilities meet customer demand with ease.

Every business is unique and needs custom automation strategies. Caja Robotics divides warehouse automation processes in four major categories.

Behind the scenes

The retail picking station process

Categories of Warehouse automation explained

Warehouse automation varies from relatively simple to quite complex. Basic automation uses planning, machinery and vehicles to reduce repetitive tasks. Advanced systems take advantage of artificial intelligence and robotics.

Warehouse automation categories include:

Basic Warehouse Automation: The focus of basic warehouse automation is assisting workers with tasks that require manual, cost-intensive and iterative labor. The assistance is provided by conveyors or carousels that are able to move items from one point to another.
Warehouse System Automation: Warehouse System Automation focuses on using software, machine learning, data analytics and robotics to sustainably automate procedures or tasks. The key focus is to analyze and review a pool of orders and boost pick-up efficiency by selecting similar items and warehouse routes.
Mechanized Warehouse Automation: Mechanized warehouse automation focuses on the interaction between humans and robotics. Robotics and systems assist humans simultaneously on regular warehousing, reducing susceptibility to errors and risk of injury.

Caja Robotics’ solution focuses on goods-to-person solutions.

Most of the work is done by our cloud-based software and our robots – Skyler™ and Sprynter™. At the endpoint of this process, machines and human workers collaborate. Our variety of workstation options that are positioned at the endpoints are designed to achieve the maximum efficiency of this collaboration. Workstations are also customizable for warehouse-specific processing needs.
Advanced Warehouse Automation:
To fully replace labor-intensive human workflows, businesses need to focus on advanced warehouse automation. By combining mechanized warehouse robotics and automation systems, Caja enables businesses to fully automate their warehouse with ease.

Caja Robotics’ two types of specialized robots work synergistically to optimize the goods-to-person system. As the Skyler™ robot can reach high shelving and the Sprynter™ robot can move fast, each of them is assigned suitable tasks. The robots move bins between workstations and shelves, constantly optimizing inventory management. Our system and robots are designed to support the concept of an Adaptive, Scalable, and Responsive system. Different types of robots give us the flexibility in tasks and navigation to achieve the best possible warehouse optimization. Our robots behave as a swarm, with the future path and locations of all robots defined to the resolution of a second.

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January 31 2022

How to Manage 2 Types of Picking Stations for Omnichannel Operations

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How to Manage 2 Types of Picking Stations for Omnichannel Operations

Warehouses, especially in the eCommerce and Retail industries, have had to adapt their modes of operation since the beginning of the pandemic in order to supply the new and rapidly increasing demand. In 2020, online retail sales accounted for 20% of all retail sales in the US, and US eCommerce sales are expected to go above $1 trillion USD for the first time this year. From keeping more inventory on hand to increasing warehouse automation, the warehouse and distribution industry has taken new form in the past years, and advanced at unprecedented speeds.

“US retail eCommerce sales will grow 16.1%, reaching $1.06 trillion in 2022. We did not forecast eCommerce reaching this milestone until 2024”

-Insider Intelligence forecast

eCommerce and retail warehouses have begun to take up more space in the warehousing market, valued at $77.57 billion USD in 2020 and increasing at a CAGR of 10% each year until 2028. However, this growth comes along with bigger challenges, especially when running omni-channel warehouses, where eCommerce and other operations are run, leaving warehouse managers looking for innovative methods and approaches to their daily operations.

Top Challenges of Running an Omnichannel Warehouse

There are many challenges warehouses and distribution centers face, especially in the eCommerce and Retail sector. Being able to tackle these challenges with innovative solutions is the key to survival and to exceptional customer satisfaction. The need for multi-channel solutions to replace outdated logistics processes can no longer be ignored, and will determine the future and growth of retailers.

Lack of Inventory Visibility

It’s difficult to track inventory when it’s spread across a number of distribution channels. Consumers are looking for products that can be delivered the same day or at the most, within 2-3 days, and keeping up with all that inventory becomes challenging, but crucial. In addition, having clear inventory visibility helps with forecasting and planning supply chain operations. Inaccurate inventory tracking can cause over or under stock levels, leaving some stock no longer relevant for sale, which also evokes problems with picker productivity.

Running Different Processes in One Warehouse

In an omnichannel warehouse, many different processes have to run smoothly in parallel. For example, store delivery and online sales, which are handled very differently on their own, must coincide and coexist frictionlessly in the same warehouse. This causes a stir in logistics for a warehouse to learn to run and optimize both approaches simultaneously.

Managing Throughput

Once a retailer’s online sales begin to boost, there is a larger need for individual orders to be picked and processed, making throughput an important part of the warehouse’s success. In order to effectively manage the number of units processed and moved, strong and efficient processes that can handle such a large volume of package processing must be implemented.

Managing Inventory Processes Manually

Manual processing of inventory can be dangerous to the overall efficiency of the warehouse. It leaves room for more human error as well as contributes to the lack of inventory visibility that hinders the success of a warehouse’s operations.

Partnering With the Wrong 3PL

Partnering with a 3rd party logistics provider can help optimize inventory and omnichannel fulfillment. Using a 3PL that understands the specific needs of the warehouse is imperative to a successful and fruitful relationship. Often, however, it can be difficult to find the right 3PL that can handle the needs of flexibility and growth in volume of orders of the warehouse.

Picking Stations for Omnichannel Operations

Caja’s AGV Solution for Omnichannel Warehouses

When it comes to warehouse automation, Caja’s impeccable AGV solution uses many different layers of algorithms to decide how to “cluster” different orders and specifies it for their picking stations – of which they have 2 different kinds: the Retail picking station and the eCommerce picking station. There is also an option for both picking stations to support omni-channel operations.

The algorithms consider robot routes, bins, and their specific locations in the warehouse, priority of orders, SKU volume needed and more. Caja’s Put-to-Light system automatically notifies the picker where to place the unit for the order on the put wall. Our advanced software can even predict future routes and orders, which simplifies picking and processing operations.

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The eCommerce Picking Station

Used commonly for eCommerce operations, the eCommerce picking station handles a high number of SKUs and multiple orders. In the eCommerce picking station, each robot brings singular bins required in order to fulfill the order. Once the unit is scanned, the Sprynter™ robot will take the bin away from the picking station and move on to its next task. This is the perfect solution for online retailers and 3PL companies.

The Retail Picking Station

The Retail Picking Station is used for wholesale and bulk orders. This picking station has the capacity to handle high volume orders with the same SKU. With these kinds of volumes, bringing the same bin to the picking station over and over again is time consuming and lowers the efficiency of the warehouse. Instead, bins that are needed will be brought once to the Retail Picking Station and taken by the Skyler™ robot as well as the Sprynter™ robot, and placed in their designated shelving system. The system automatically instructs the picker on which items to pick and which order bin to place the item.

Hybrid Mode

This unique picking mode conducts the activities of both the eCommerce and Retail picking stations in one. In the Hybrid Mode, both types of robots bring bins and participate in the outbound process. Caja’s software will instruct the picker on when to pick from the Sprynter™ robot and when to pick from the station shelves.

Caja’s Warehouse Automation Solving Omnichannel Problems

Caja’s comprehensive solution enables warehouse managers to run multiple processes in parallel while maximizing inventory visibility and increasing throughput efficiency. Since the technology is used across a wide variety of use cases, warehouses can be sure to manage their processes with ease and understand exactly what needs to occur and when. It is the perfect solution for warehouses trying to channel multiple, complex fulfillment operations under one roof in order to supply the best service to their customers.

Article

What is warehouse automation?

Warehouse Automation

What is warehouse automation?

Automating global warehouses

How does warehouse automation work?

The retail picking station process

Categories of Warehouse automation explained

Warehouse automation categories include:

Get in touch

How to Manage 2 Types of Picking Stations for Omnichannel Operations

How to Manage 2 Types of Picking Stations for Omnichannel Operations

Top Challenges of Running an Omnichannel Warehouse

Lack of Inventory Visibility

Running Different Processes in One Warehouse

Managing Throughput

Managing Inventory Processes Manually

Partnering With the Wrong 3PL

Caja’s AGV Solution for Omnichannel Warehouses

The eCommerce Picking Station

The Retail Picking Station

Hybrid Mode

Caja’s Warehouse Automation Solving Omnichannel Problems

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