If you are thinking of expanding your warehouse operations, then you may want to consider installing an automated picking system. Instead of having warehouse staff pick items to make up customer orders, an automated picking system will remove the products from storage and pack them for you. There are many benefits of having an automated picking system, which we will now go on to explain.

Save your business time and money

Integrating an automated picking system with your current order system can save a lot of time and money. It will dramatically cut down your labour costs, as you will not need to employ as many staff to work in your warehouse.  Picking systems are able to do the job much quicker, enabling you to pick, pack and process a higher volume of orders each day.

The fact that the system is paperless also means that you will save money that you would usually have to spend on paper for your ticket printers. It is a much more environmentally friendly way for your warehouse to operate.

Accurate order management

Another benefit of integrating a picking system with your order management system is that it will automatically update quantities of stock. This means that you will always know exactly what stock is being held in your warehouse. You can set your system up so that it automatically updates product quantities on your website, so that customers do not face the problem of trying to purchase something that is actually out of stock.

Along with increasing overall efficiency, warehouse automation can also prevent costly mistakes. Picking systems are much less likely to make errors, therefore ensuring that your customers receive exactly what they ordered. Mistakes can not only be financially expensive for your business, but they can also put your reputation at risk.

Bespoke picking systems

There are many different picking systems to choose from. The type you choose will depend on the characteristics of your warehouse. In order to get the most benefits out of using a picking system, you may want to consider having one custom made for your warehouse. This way you can ensure that the design is tailored to meet the needs and requirements of your business. A bespoke picking system will improve the functionality of your warehouse and make better use of the space.

Automated picking systems can save your business time and money, whilst also improving efficiency and raising productivity. Having a bespoke picking system made will improve the way your warehouse works and facilitate the future growth and expansion of your business.

Spring is the perfect time to sort out your warehouse and get everything in order. You simply cannot put off that warehouse clean any longer! If you have been staring at a pile of items that need sorting through or have been thinking of making improvements to your warehouse for a while now, there couldn’t be a better time to do it.

Not selling

Rather than ignoring the pile of stock you cannot seem to shift, you need to make a decision on what to do with it. Perhaps think about putting it on sale in order to try and attract customers to buy it. Alternatively you may want to think about giving it a shelf life. Many businesses find that they have a pile of damaged stock in their warehouse taking up valuable space. With damaged items you either have the option of offering them at a heavily discounted price or throwing them away.

Re-organising your warehouse

Sometimes the smallest changes can make the biggest difference in improving the efficiency of your warehouse operations. Moving pallets and storage racks to different locations in your warehouse can often make things flow a little better. Make sure you listen to your warehouse staff when making changes to improve your picking process, as they are the people who do the job on a daily basis. Your top selling products should be in the most convenient location to pick, with your least popular products being positioned further back.

Cleaning your warehouse

Clean warehouses tend to be safer, more organised and more productive. When doing a spring clean of your warehouse be sure to use a floor sweeper and cleaning products to remove the build-up of dust on the floor, pallet racks and any other shelving. It is also important to ensure that all debris and old packaging is thrown away or recycled. Simply leaving it lying around your warehouse could cause accidents as it may reduce visibility for forklift drivers or be tripped over by one of your employees. Your warehouse should be cleaned and tidied on a regular basis in order to keep it in tip top shape. Creating rotas and making cleaning products readily available are both great ways of encouraging your staff to keep their working environment clean and tidy.

Plans for the future

Whilst doing your spring clean you may find yourself thinking of how you can improve the efficiency of your warehouse in the long term. Automating your warehouse operations with pallet conveyors and picking systems is a fantastic way to improve productivity, especially for those businesses looking to increase capacity and become more competitive.

Over time we have seen a dramatic charge in the way warehouses are managed. Developments in technology have meant that businesses are now able to manage their stock much more efficiently and meet the high demands of orders that come in through various channels including online sales.

Looking back at warehouse management

In the past warehouses were not full of all of the advanced technology we are so used to seeing today. Instead everything was done manually. Rather than having computerised inventories, warehouse staff would use paper filing systems to keep a record of every product stocked in a particuler warehouse. Obviously these records needed to be constantly updated as deliveries came in and products were shipped out.

The job of a warehouse worker was much more labour intensive. Products had to be physically picked by people reading hand written picking lists and tickets. Obviously with people picking products by hand it meant that warehouses had to be organised so that all products were in reach. Having a more labour-intensive workforce meant that companies were more prone to human errors and were not capable of producing the same levels of output that the advanced technology aids us in doing today.

Modern day warehouse management

Today most companies use advanced technology systems to help them run and manage the various operations taking place in their warehouses. Pretty much everything is computerised, though there is still a need for workers, but nowhere near as many as would be required in the past. Inventories are now stored on computers and are usually linked up to a company’s ERP or order management software. This enables them to be automatically updated as products are sold in-store or via a company’s website.

The process of picking is also automated using barcoding and conveyor systems which transport packaging to various stations around a warehouse. More often than not warehouse employees use handheld barcode readers, scanners and even voice recognition technology to help them pick products, identify what’s in stock and send messages back to the order management software.

Advantages of automated warehouse systems

One of the greatest advantages of automated warehouse systems is that they allow businesses to increase their capacity and output. Warehouses run much more efficiently than in the past and there is a reduced risk of human errors being made. With an increasing number of people choosing to shop online, it is now more important than ever for businesses to automate their warehouses in order to keep up with demand. Conveyor belts, picking systems and barcode readers enable companies to efficiently pick and pack their customers’ orders, whilst automatically updating their order management software, in-store till systems and online websites.

Our press release for Ecommerce sites meeting Christmas demand is here: http://uk.prweb.com/releases/automatedwarehousesystems/keymas/prweb10261021.htm

Read how the rapid growth in ecommerce sales has had a significant impact on midlands based, Keymas Ltd, leading provider of automated warehouse systems in the run up to Christmas 2012 press release we have put out. The aim is to showcase our Ecommerce area of growth for our automated warehouse systems.

Pallets are usually made from two layers of wooden slats and are used by businesses to transport and store heavy products and materials. Often warehouses have pallet conveyor systems which enable them to transport goods both safely and efficiently. Unfortunately once businesses have finished using their pallets they are often simply thrown away. Here at Keymas we know that many of our clients use wooden pallets so we thought we would share a few ways you can effectively recycle them, whilst creating new things for your home!

Pallet Furniture

Whether you are a DIY pro or simply fancy trying your hand at a new hobby, there are plenty of things you can do to give your wooden pallets a new purpose. Many people creatively turn them into furniture for the home. By simply turning a pallet on its side, you can transform it into a shoe rack, or why not attach it to your kitchen wall and make a country-style spice rack? The wooden slats are perfect for shelving, housing books, plates or anything else you would like to have on display.

Pallet furniture

Whilst it is fun to see what new things you can make for your home, it is also important to make sure you treat and sand the wooden pallets, so they are safe to use. Give your pallet a lick of paint and it will look as good as the expensive shabby-chic furniture that is oh-so-popular in the latest home ware magazines.

Great for the garden…

Not only can wooden pallets be transformed into furniture for the home, but you can also create fantastic outdoor furniture, perfect for garden parties and barbeques in the summer. Simply use a saw to chop your palettes into sections, attach legs and sand them down for safety. Throw on a few cushions for extra comfort and you are good to go. Stain your newly made furniture with a colour that matches your shed or fence. You could even create matching plant pots, bird tables and compost bins!

Pallet chairs

pallet chairs

It is amazing to see what you can create with a simple wooden pallet. Whether you are looking to construct unique furniture or something a little quirky like a handmade doll house or pet bed, you will benefit from saving money, whilst also doing your bit for the environment. If you own a business that uses wooden pallets, why not encourage your employees to take them home for free, or offer them to your customers? This is a great way to save on the costs you would usually pay for disposal.

The run up to Christmas is the busiest time of the year for warehouse staff and arguably the most stressful. The peak in trade means that businesses are under pressure to deliver goods to meet increased demand and achieve festive targets. Now is the perfect time to ensure that your warehouse is organised. Your system should be both practical and efficient which translates to simple to understand and easy to use.

Keeping an up-to-date record of your inventory is an important basic to adhere to.  Make sure that you record every product that you have in stock along with the quantity. Divide products into categories depending on their size, weight or even popularity. If you have too much of one product, why not consider putting it on sale to make room for new stock?

Warehouse management

Even the most experienced warehouse staff can make mistakes during the picking process so it is important that you use labels and barcodes to keep track of your stock. Linking your barcodes up to your warehouse management system will ensure that quantities available are automatically updated, so you are aware of low stock levels. Setting up automatic re-ordering may also be possible. Barcodes provide quick and accurate data processing making your handling, picking and distribution systems more efficient. Labelling products is also a good idea, especially if you have new temporary staff working over the Christmas period. For best practice ensure your labels coincide with aisles and shelf numbers, to make products easier to find.

Pallet Racking

Whether you are a large or small business you will benefit from some form of pallet racking. Pallet racking is an efficient and safe way of stacking your stock, preventing it from unnecessary damage. Whilst it is a fantastic way of storing your products, it is essential that you carry out regular inspection to ensure that your racks remain intact and that any damage is recorded and repaired immediately. The more organised your warehouse is, the more products you can store and potentially sell.

Larger warehouses may also benefit from installing a conveyor system. First decide what needs to be achieved, enabling you to determine whether you require a simple conveyor layout or a more extensive design that covers the whole of your warehouse. Conveyor systems are compact and improve the use of space, enabling you to achieve smoother and efficient transportation of stock.

Although the run up to Christmas is a busy, hectic period it is important that you ensure that your staff are complying with safety guidelines and regulations. The cleaner and more organised your warehouse is, the happier and safer your staff will be, raising both morale and productivity.

Although it would be a fun direction to go in, we at Keymas arn’t developing miniature conveyors but a bit of fun with tilt-shift photography (Tilt–shift photography is the use of camera movements on small- and medium-format cameras, and sometimes specifically refers to the use of tilt for selective focus, often for simulating a miniature scene. More info here).

Here is our gallery of ‘minuture conveyors’ (Actually our normal conveyor system images but with the tilt-shift effect applied), just for fun. Click on the image to see the bigger versions.

Keymas K-Store: an application to rejuvenate your warehouse

• Examine your current warehouse operation
• Talk to your pickers!
• Consider Zoning
• Implement Keymas K-Store

 Examine your current warehouse operation

So, you have a warehouse and want to make it run as efficiently and effectively as possible. Let’s look at the warehouse: The goods are stored on racks that are arranged in rows and are on multiple levels. There’s a standard distance between the racks allowing access to human pickers and forklift trucks. Pickers are given a paper copy of an order and then pick the items on the order from the racks. Your warehouse also has clearly & methodically labelled racking and the pickers are experienced and used to the layout of the warehouse.

Other factors in the picking equation might include:

• How many rows of racking or shelving does the warehouse have?
• How many pickers are there and how are their routes organised currently?
• How many items are stocked?
• Are there bulky and/or weighty items unsuitable for manual handling?

All these factors need to be considered to optimise a picking system. Taking an overarching approach will give you the best overview of how your current system works.

Talk to your pickers!

Talk to your pickers! They are the people who walk up and down your aisles day after day. They will have a good idea of what is picked. If prompted they may also tell you a few home truths about your system. For example, illogical racking locations of goods meaning they have to walk extra distances when picking compatible items. This sort of constructive feedback can be used to improve the overall performance of the system.

Consider Zoning

Carefully consider zoning, i.e. placing certain items in one specific zone or area. Perhaps the items are related or combined, or maybe you want to keep heavier/bulkier items in one location. Whatever the reason, it means you’re starting to closely examine what goes where and why. That is good.

If you have access to past order data, collate this into a format that allows you to examine it in detail. If certain goods are often ordered at the same time locate them near to each other. Past data will allow you to assess if this happens, how often, and whether it is actually feasible to locate the goods close to each other.

Once you have your zones organised, ensure that they are used effectively. The best way to do this is to have as few pickers as possible walking in the zone to reduce congestion. To do this, your order picking system needs to be refined so that the picking routes identify which picker(s) operate in which zones. This is where things can start to get complicated!

Implement Keymas K-Store

One way of simplifying this whole procedure is to implement Keymas K-Store. K-Store has been designed from the ground up to streamline warehouse operations; from goods in all the way through to despatch. Employing barcode and wireless technology run through ordinary PC workstations; using K-Store goods can be handled in the most effective way possible as they pass through your warehouse. Picking routes are just one way in which systems can be enhanced.

Taking a typical order processed with K-Store, your pickers will be given their orders via hand-held scanners. These scanners will tell them on a screen what is to be picked, where it is located, which particular batch of a product is to be and where it is to be packed. Because each product is scanned as it is picked, if a picker makes a mistake they will be told so instantly and pointed to how and where they can correct the error.

Add zoning into the equation and you have a warehouse that will be operating very efficiently indeed. Paper-based picking offering no such sophistication will be a thing of the past. K-Store will also update your stock levels instantly, enabling you in time to tweak your buffers to optimal levels, saving you even more.

Once K-Store is up and running, operators will know that their pickers are using routes and zones that are efficiently planned and make best use of their time; goods will be handled in a way that takes into account their shelf life and fragility; K-Store can produce reports on demand showing what was picked, when and by whom.

There are some prerequisites before K-Store can be implemented:

1. First and foremost: a commitment to make it work from all concerned
2. The means to barcode every product entering & leaving the premises and every product location within the premises.
3. An honest self-assessment of the current operation and clearly thought through ideas on how you want it to operate after K-Store implementation
4. In conjunction with 3, the ability to move products, where necessary, into zones, and to implement other changes necessary to streamline operations

Keymas K-Store is our application for managing warehouses. Operators implementing K-Store are given full control of their goods; from goods in, via sophisticated stock control features, all the way to despatch.

Combine K-Store with a physical makeover of your existing warehouse system and you will have a very sophisticated system delivering total control of your material handling operation. Contact us now for a no-obligation consultation and rest assured that we will make our solutions fit your needs – not vice-versa!

Most people are familiar with the term Lean Manufacturing: the elimination of waste from manufacturing processes and, in the process, simplifying and adding efficiency to those processes. Lean automation borrows those principles and applies them to automation.

Furthermore, lean automation allows owners to easily improve the performance of their systems and to introduce scalability to them. They can also use the data transparency that lean automation gives them to, e.g. generate, performance reports, assess the impact of changes or to gauge the effectiveness of cost reducing measures.

So, if lean automation is such a dramatic measure, how is it achieved? The answer is a combination of two technologies. Bus-based control wiring systems in control panels is one of these technologies; the other being the integrated HMI/PLC.

Bus-based wiring replaces the traditional “spaghetti” of wiring found in older control panels and replaces it with just one bus cable that runs around the components in the panel. Indicator lights, switchgear, motor starters and inverters are examples of parts that can be wired into this single loop. Now, instead of a jumble of wiring linking to the PLC or smart relay at the heart of the control system, the bus cable acts as the single link and almost removes the need for conventional inputs and outputs to the system.

In addition, should you later wish to expand or modify your system, all you need to do is plug or unplug components into the central bus cable. Scalability comes as standard and the bus cable technology allows you to plug modules into the system instead of having to rewire or “plumb in” a new component group.

Being a bus cable, it not only carries control signals to the various components, but it also transmits data. Every action carried out by the system can be carried to logging systems or …. Theoretically at least, total data transparency can be achieved.

So, that’s how bus cable technology can transform control wiring, but how does the integrated HMI/PLC help? The very existence of such devices depends on bus-based control wiring systems, meaning that only minimal provision needs to be made for conventional inputs and outputs. The formerly separate HMI and PLC functions can now be combined in just one unit. At a stroke, cost and space savings are made, but, crucially, programming is greatly simplified.

Choose your HMI/PLC product carefully, and you’ll have the ability to exchange data with external systems. What was once a very clever, but isolated piece of automated machinery can now be brought into the data fold of large-scale production plants. Communication with other IT systems is possible, so you can link to systems responsible for, e.g. quality control and order scheduling.

Lean automation is already having repercussions in the design of automation systems. “Traditional” automation systems have an architecture that includes a core PLC and a standalone HMI with a spaghetti of wiring both in the control panel itself and in the field. An obvious disadvantage of this architecture is the amount of time it physically takes to wire up. Less obvious is the fact that modifying or upgrading such systems is complicated and thus costly. In nearly all such systems, data transparency is, at best, at a poor level, because the control wiring is not capable of, nor designed to, transmit data to the PLC.

Acknowledging these shortcomings, designers started to use fieldbus systems, instead of the more commonplace field wiring, in conjunction with remote input/output modules. Clearly, this reduces the amount of field wiring and builds in greater flexibility and fieldbus systems can offer data transparency. However, there is still the “spaghetti” in the control panel to consider. The complexity of this wiring makes system modifications complex and although individual components within the control panel offer data transparency, in practise harnessing these data is often difficult, because the sheer amount of wiring renders the components inaccessible.

The implementation of lean automation has been made easier today, by using bus-based control wiring and integrated HMI/PLC devices within control panels. Combine this with the fieldbus systems and remote input/output devices mentioned above – all now commercially available – and nearly all the prerequisites for lean automation, i.e. data transparency have been achieved.

Control wiring is greatly reduced within control panels, so less space is needed inside them. Less wiring means less cost and system flexibility is greatly enhanced. Key automation components are now linked to the PLC via the bus-based wiring, so data transparency and exchange are now a given. This makes it possible to implement actions such as complicated product changeovers on a machine automatically and remotely, thus doing away with costly manual resets.

Looking to the future, it will soon be possible to further enhance lean automation. Single bus-based systems will appear to eliminate the need for a separate fieldbus. When this is achieved, the holy grails of total lean automation and complete data transparency will be upon us. Cost savings will be significant, as will increases in system flexibility. Once this stage is reached, designers will have all the tools at their disposal that they have identified as essential for future automation systems.

The lure of lean automation means that designers are already integrating the concept into their products. As time goes by, there will be further improvements and developments, but there is nothing to stop earlier adopters from benefitting now from the gains to be made. Components and technologies are on the market now to deliver almost totally lean automation. By building them into new systems, companies will be buying themselves a competitive edge and gaining industry market share, which can only be to their benefit.

Please browse the image archive slideshow above.

Keymas Ltd is celebrating 25 years in the warehouse automation and conveyor industry.

We are celebrating the 25th year of innovation within the control and automation sector with Keymas Ltd reaching the proud age of 25. We are thankful to the individuals and companies that have made it possible to grow the company over the last 25 years.

Starting in 1986 founded by John Barton, as a control systems software company, Keymas Ltd has become a leader in warehouse automation, conveyor control, integrated warehouse software and complete warehouse projects. Reflecting on the 25 years since it