Interest in warehouse automation generally and robotics specifically is high, driven by continued labor issues in terms of availability and costs.

Some companies are fortunate enough to build new greenfield facilities, with fewer constraints than are found in adding automation to existing facilities, often termed “brownfield” sites.

But the reality is that thousands of existing distribution centers could benefit from warehouse automation and improved warehouse software solutions, versus a much smaller number of new greenfield projects launched each year.

Other blogs in this series from the MHI Solutions Community have looked at different aspects of adding automation to those existing sites to optimize warehouse operations and warehouse processes. This blog will look at the critical topic of software for automating brownfield operations.

Of course, in reality, the details matter, with “adding automation” covering a lot of potential ground, from say adding a simple print-and-apply line to a significant goods-to-person system and everything in between or beyond. The discussion on this topic would naturally vary depending on the scenario.

That said, we can share some insight for a generic automation deployment.

Why Warehouse Software Is Central to Brownfield Automation

Central to the deployment of brownfield automation are the capabilities of the current WMS and its ability to deliver along two dimensions:

• Real-time integration/messaging with the automation software
• Its functionality to support the to-be process definition

In the past, when the existing warehouse management system (WMS), due to its age or other factors, couldn’t support the automation plan there were three basic options:

(1) implement a new WMS as part of the automation program, greatly expanding its cost and scope

(2) modify the existing WMS to close the integration and/or functional gaps – generally a risky proposition

(3) kill the project once the WMS deficiencies are identified.

Understanding the Role of Your Existing WMS

But in recent years, a new option has emerged, which involves what is typically referred to as a Warehouse Execution System, or WES.

Greatly simplifying, a WES can often enable a company to keep much of its current WMS functionality (e.g., receiving and other inbound processes, putaway, inventory management) when automating. A WES will act as integration middleware between the current WMS and the automation, and then taking over real-time execution of new and now automated fulfillment processes.

Real-Time Integration Requirements

That middleware capability should include broad flexibility in terms of how the WMS will be integrated with automation software, from use of modern APIs to web services, flat files, to everything in-between.

Warehouse automation projects often rely on seamless integration between software solutions and material handling equipment to ensure minimal disruptions and real-time data visibility.

Functional Gaps and Risk Areas

Whether a company’s existing WMS can satisfactorily support the integration and functional needs of the new automation system will depend on many factors, including:

• The nature of the requirements themselves
• The origin/type of WMS (homegrown, legacy, modern commercial package, etc.)
• The age/technology of the WMS

WES and Middleware: A Bridge for Integration

For example, on the first point, will wave planning be required? If yes, can the existing WMS do that order planning? Or will a WES or other type of automation software be needed to provide those capabilities?

Which begs the question: How will the orders be sent from the WMS?

• As just an order batch/stream, with all planning and execution performed by the automation software?
• Pre-planned, typically as a wave?
• Full cartonization – with the WMS sending what should go in each box?

For example, the existing WMS may be able to do the first but not the second.

Emerging Solutions and Multi-Agent Orchestration

So-called brownfield sites present some challenges on the software side of the equation. Those range from common limitations along two dimensions: real-time integration and functionality, especially in a new world in which automation increasingly involves autonomous mobile robots (AMRs) with a new set of integration and software capability requirements, that are more complex than traditional conveyor sortation and AS/RS system integrations.

Questions to Ask Before Implementing Automation

The ability of a company’s existing warehouse software to meet the new requirements is the question, and the lack of full vetting of those requirements is a common source of later cost, schedule and functional challenges. Questions you should prepare to research are:

• Can your current WMS or warehouse software support real-time data exchange with automation tools?
• Are there integration gaps between your existing systems and new automated hardware like AMRs or fully automated conveyor systems?
• Does the software support wave planning, barcode scanning, order picking, cartonization, and real-time visibility across processes?
• Can your software scale with long-term automation goals and help reduce manual labor, or is it limited by age or architecture?
• Will you need middleware such as a WES to bridge functionality gaps, optimize resources, or enable machine learning and autonomous workflows?

Failing to fully vet these questions early is one of the most common causes of delays, budget overruns, and performance issues in warehouse automation projects.

Final Thoughts on Software Strategy for Existing DCs

Automation has successfully been added to thousands of existing distribution centers over many years.

In general, significant modifications to an older WMS to theoretically close the gaps is a path to be avoided.

Fortunately, newer solutions such as Warehouse Execution Systems provide additional options for meeting integration and functional needs, but a word of caution here as well, as there are many definitions of WES, and any vendor can and does call whatever it wants a WES, with widely disparate capabilities under that umbrella.

Functional and integration risk increases with the age and lack of capabilities of a company’s WMS, a real issue from automating many existing facilities. Due diligence is needed on the functional and integration requirements for the project, the ability of the current WMS to meet those requirements, and alternatives such as WES if the gaps are significant.

Taking shortcuts in this process can lead to challenges, while those who do it right enjoy the benefits of brownfield automation faster and more fully.

For more information about the Solutions Community: mhi.org/solutionscommunity

For further articles from the Solutions Community:

What is CMMS? Usage-Based Maintenance for Modern Warehouses

All You Need to Know About Yard Management Systems (YMS)

How to Implement Automation in Brownfield Facilities Without Disrupting Operations

MHI Solutions Community Annual Meeting Panel

The Many Advantages to SaaS

Integrating New Automation

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