Integrating New Automation
Implementing new equipment will yield significant benefits, but the process can be disruptive if not well coordinated.
Whether you are expanding your existing automation or embarking on a new automation journey, the anticipated outcomes—enhanced production and savings, reduced errors/quality concerns, and the opportunity to upskill your workforce—are promising. However, the path to achieving these goals can be challenging. By taking certain measures, you can prepare yourself for success.
Documentation of Current Processes
One of the initial steps is to meticulously document your current processes, particularly when implementing software such as warehouse management systems (WMS) or warehouse control systems (WCS). Proper documentation is crucial for your OEM or integrator to assist you effectively; without it, the implementation process will be more time-consuming, labor-intensive, and realize scope creep due to lack of visibility. As a result, your initial budget expectations could be overwhelmed with “runaway costs”.
For starters, performing a comprehensive assessment of your operations as a baseline is necessary. Identify the issues you aim to resolve—whether it’s limited space or bottlenecks in material flow. Identifying suggested changes along the way by end users is beneficial to implementing positive overall changes. Documenting and taking photos when necessary for all process improvement opportunities and understanding them thoroughly in order to communicate them to your automation partner is paramount.
Your process documentation should map the entire operations, from receiving to shipping. Regardless of the current level of automation, describe the operation and create a functional specification of all material movements. Additionally, review any written procedures and ensure your staff comprehends and adheres to them. Establishing this foundation with your current systems will facilitate the adoption of new systems.
For example, when scanning a label, determine what information is being collected and how it is tracked through the WCS. Document the operations, workflows, and necessary changes to integrate your employees into the new system.
Collaborating with Your Partner
With comprehensive documentation, your partner can develop optimal solutions to address almost all of the pain points. Together, you can collaborate on the best course of action and commence implementation.
Minimizing Disruption in Brownfield Environments
If you are operating in a brownfield environment, it is essential to implement new automation without disrupting ongoing operations. Develop a detailed plan with consideration tophasing in the new automation with contingency plans in place. This can help adapt to the change more easily while also mitigate unforeseen failures. If a phased approach is not feasible, consider the operational hours of your facility. Identify idle times, such as during shifts or weekends, to roll out the new automation keeping away from peak periods.
Integrating Multiple Automation Systems
If your automation involves multiple providers or phased implementations, ensure you have overarching software that can communicate with all automation systems. Typically, this will involve a host system like a WMS, potentially working in conjunction with a WES, ensuring compatibility with all specific software components of the new automation. Be sure to plan for continued success with daily and regular preventative maintenance plans in place.
Integrating new automation is how organizations excel and keep ahead of their competition, but it requires careful planning and consideration.
For more information about the Solutions Community: mhi.org/solutionscommunity
For further articles from the Solutions Community:
Don’t Overlook the Condition of Handhelds
Integrating New Automation- Part 1
Implementing a Warehouse Control System (WCS)
Is it the Right Time to Automate Your DC?
Condition Monitoring is Expanding
Warehouse Execution Software Implementation
