When setting up a new site, whether it’s a distribution centre, a manufacturing facility, or a fulfilment hub, effective planning of automation and conveyor systems is critical to achieving efficiency, scalability, and cost-effectiveness. A well-designed system can optimise workflow, reduce manual handling, and improve order fulfilment accuracy. Below, we explore key considerations for organisations planning automation for a new site startup.
Optimising available space
Space is a premium resource in any facility, and making the most of it is essential for operational efficiency. Warehouse and factory layouts should be strategically designed to maximise storage and workflow. Some key considerations include:
- Vertical space utilisation: Many facilities underutilise their vertical space. Mezzanine floors can significantly increase storage capacity while allowing automation systems to transport materials efficiently between levels.
- Office space layout: Office locations should be planned to ensure they do not encroach on valuable warehouse space. Well-thought-out office designs should provide an optimal balance between administration functions and operational efficiency.
- Aisle optimisation: Proper aisle widths must be maintained to accommodate automation equipment, forklifts, and personnel, while ensuring smooth traffic flow and maximising storage density.
Automated storage solutions
Automated storage and retrieval systems (AS/RS) enhance warehouse efficiency by reducing picking errors, minimising space requirements, and improving overall throughput. Organisations should consider:
- Vertical lifts: Ideal for space-saving storage of small to medium-sized items.
- Shuttle systems: High-density storage solutions that improve order picking efficiency.
- Carousels: Suitable for high-speed picking environments requiring fast access to stored inventory.
Conveyor systems for seamless material handling
A well-planned conveyor system ensures smooth and efficient movement of goods within a facility. Key considerations include:
- Conveyor routing: The layout should minimise bottlenecks while efficiently linking different operational areas.
- Scalability: Conveyor systems should be designed for future expansion to accommodate business growth.
- Integrated Control Systems: Smart controls ensure optimal conveyor speeds, flow control, and automated sorting, reducing the need for manual intervention.
Automated picking and packing Solutions
The integration of automated picking and packing solutions can significantly improve productivity and order accuracy. Options to consider include:
- Pick-to-Light and Put-to-Light systems: These technologies guide operators to the correct items, reducing errors and increasing efficiency.
- Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs): Ideal for reducing manual transport and increasing order fulfilment speed.
- Automated packing machines: These systems streamline packaging processes by automating box erection, filling, sealing, and labelling.
Future-proofing your investment in automation
When planning automation for a new site startup, you should consider long-term flexibility and adaptability. Key strategies include:
- Modular Designs: Implementing scalable solutions that can adapt to evolving business needs.
- Data and analytics: Leveraging warehouse management software (WMS) and real-time data tracking for continuous optimisation.
- Energy efficiency: Selecting energy-efficient automation equipment to reduce operational costs and environmental impact.
Conclusion
Effective planning of automation and conveyor systems for a new site startup is crucial to operational success. By optimising space, integrating advanced automated solutions, and ensuring scalability, organisations can maximise efficiency and futureproof their investment.
CSL Automation specialises in designing, installing, and maintaining bespoke automation solutions for businesses looking to enhance their operational capabilities. To discuss your automation requirements, contact us at [email protected] or call 01283 55 22 55.
