Simulation is the starting line for warehouse evolution
Amazon just released its new Vulcan robot, a next-level machine with a sense of touch that can grab items in a warehouse. It’s been described by the corporate giant as a “fundamental leap forward in robotics” to speed up item picking for storage and delivery.
But let’s be real: most warehouses don’t have Amazon’s financial firepower to throw at robot R&D for complete revolution. For the vast majority, success in the immediate future comes from smarter moves, not bigger leaps.
What’s needed right now is to squeeze every bit of value from what’s already in place with a little help from next-generation simulation digital twin technology. In the short term, that means seeking out evolutionary progress.
A blend of humans and machines
Most warehouses and logistics operators aren’t going to flip to full automation overnight, and that’s fine. A blend of humans and machines will stay the norm, and there are plenty of good reasons for this.
Big upgrades in one fell swoop can risk business continuity. For example, if a manual picking process is being swapped out for a fully automated robotic system, has it been effectively integrated with storage areas and conveyors so the right items can be selected? Any errors could slow down throughput of items and lead to delivery delays. While machines may be able to check for signs of a spoiled batch or potential contamination, cost implications, regulations or a lack of trust in the technology can prevent this from being an option for some.
In the pharmaceutical industry, contamination checks are a legal and regulatory requirement. Humans and machines work in tandem, with people overseeing critical control points and ensuring compliance.
When negotiating some of these barriers, smaller, carefully thought-out steps towards automation, with humans overseeing the process, can present a way forward. Simulation lets you optimise and improve these hybrid setups step-by-step. You can test and train with digital twins that mirror your real warehouse operations. This lets you trial alternative robotics solutions for their potential ROI and how they support humans and existing processes on the warehouse floor, or any other change, before you risk a penny.
Operational tweaks for cost-cutting and efficiency
Sometimes, the smartest move isn’t robots at all, but an operational tweak that cuts costs and cranks up efficiency. For example, it could be a case labeller not moving fast enough to keep up with the warehouse’s operational pace, which then impedes the efficiency of pick stations afterwards. Throughput could simply be increased by incorporating a second case labeller.
Next-generation simulation digital twins put the power in the hands of every player, whether it’s an operational leader or a member of the floor staff. They deliver a crystal-clear view of how your warehouse will perform tomorrow. The people on the ground who know the processes inside-out can make decisions with confidence, whether it’s redeploying people or investing in automation.
And, in addition to immediate evolutionary steps by making use of current infrastructure, simulation can lay the groundwork for revolution later down the line. With operational processes laid out in a virtual environment, you can assess where you may need to make a replacement in the next few years and start to plan the build and rollout of a new solution. And it may be that after a period of time, a revolutionary solution like Vulcan is both commercially available and more affordable, allowing you to benefit from its capabilities.
The future of warehouse operations
Right now, the pressure is on for all warehouse teams to be doing more with less, and this challenge doesn’t show signs of dissipating any time soon. Identifying ways to make your existing setup better, faster and leaner will deliver a much-needed competitive edge. The right tools help warehouses of any size find cost savings, sharpen processes and weave humans and machines into a high-performing team. There are always opportunities to lay a path for revolution further down the road. Right now, the other 99% can keep pace by optimising what they already have.
