Automated Material Handling Systems Guide

Automated material handling systems (AMHS) are improving the efficiency of warehouses and distribution centers by increasing throughput and reducing labor requirements. Supply chains are using automated material systems to improve their competitiveness and customer satisfaction. They are upgrading slower, manual, and labor intensive processes to become more efficient. Let’s review 12 popular automated material handling systems, popular types, and current trends.

Automated Material Handling Systems Types

1. Conveyor Systems
2. Automated Mobile Robot (AMR) Systems
3. Automated Storage and Retrieval Systems (AS/RS)
4. Palletizer Systems
5. Pick to Light and Put to Light Systems
6. Sortation Systems
7. Packaging Systems
8. Dock Systems
9. Robotic Systems
10. Carton Flow Systems
11. RFID and RF Scanning Systems
12. Material Handling Software

Conveyor Systems for Automated Material Handling

Automated roller conveyors are a popular automated material handling system that uses belts or motorized rollers to drive goods along the conveyor line. This system allows automated control over the speed and direction to transport boxes, cartons, and other packaged items. Conveyor systems are a very efficient solution for transporting goods between warehouse areas such as racks, picking stations, consolidation stations, and shipping docks.

Popular types of conveyors are –

1. Belt conveyors use a motorized belt to transport goods. They are often used where goods movement is linear between two or more points. Also used when tote or case location on the belt is critical.
2. Motorized Drive Roller (MDR) Conveyors offer increased control and efficiency. Their rollers can be arranged for turns and angles. The rollers can be energized as needed.
3. Pallet Conveyors are built with heavy-duty construction with larger motors to transport goods stored on pallets.
4. Accumulating Conveyors feature zones of rollers that can be individually controlled to gather and release items. This allows for a controlled flow of goods without stopping the entire conveyor line.
5. Vertical Conveyors, also known as vertical reciprocating conveyors (VRCs) and Spiral Conveyors, transport goods from one level to another. They are typically found in warehouses and distribution centers that have mezzanine levels.
6. Overhead Conveyors are conveyors that are mounted overhead and save floor space. They are typically found in manufacturing, where floor space is limited.
7. Modular conveyors offer greater flexibility for operations as they can be easily reconfigured. This is helpful for growing and changing businesses.

Conveyor trends are focusing on enhancing efficiency, flexibility, and sustainability. They are integrating advanced control systems and software for efficiency. These material handling systems adjust conveyor speed, routing, and accumulation to maximize throughput and minimize bottlenecks. More modular roller conveyor system types can now be easily reconfigured or expanded to adapt to changing warehouse needs.

Automated Mobile Robots (AMR) Systems

Automated mobile robot (AMR) systems are autonomous robotic systems that excel at moving goods. AMRs use sensors, cameras, and navigation systems to move through a warehouse. They assist with tasks such as goods transportation, order picking, inventory management, and pallet handling. AMR material handling systems are increasing in popularity due to their flexibility. The AMR as an automated material handling system, easily adapts to changing environments.

Types of AMR Systems include:

1. Goods-to-Person Robots or shelf-picking robots bring items directly to workers at picking stations. They will move under a rack of goods, lift them up, and bring the goods to an operator. They reduce the labor associated with manually transporting goods from one point to another and wasted walk and search time. An example of this AMR system is the Go-Fer Bot.
2. Pallet handling AMRs are larger AMRs with heavier construction and stronger drive systems to move heavier loads.
3. Autonomous forklift AMRs are driverless forklifts that are equipped with robotic arms or forks for lifting and moving palletized goods.
4. Pick-Assist (PA) AMRs are mobile robots that work alongside human operators. These mobile collaborative robots can replace manually operated picking carts to increase warehouse efficiency.
5. Shuttle AMRs can raise up to over 25 feet to retrieve cases or totes from racks with grippers. These AMRs, such as the Stacker Bot, move goods to and from racks, conveyors, workstations, order fulfilment, and other automated material handling systems.
6. Auto Fulfillment AMRs use conveyor on their top surface to automatically transfer goods. They can adjust their height for automated transfer.

Current trends with AMRs include advancements in navigation technology, such as with simultaneous localization and mapping (SLAM) algorithms. This enables robots to navigate easier with warehouse changing layouts and obstacles.

Another trend is with improved AMR integration. This can be across a fleet of AMRs of different types, manufacturers, and other automation systems. A warehouse execution system (WES), such as New Horizon, enables this quick smooth integration.

Automated Storage and Retrieval Systems (AS/RS)

Automated Storage and Retrieval Systems (AS/RS) are automated material handling systems for storing and retrieving goods. They use a combination of storage racks, shelves, robotic mechanisms, and control systems to automate the movement of items. AS/RS systems are very efficient in maximizing storage density, throughput, while reducing labor requirements.

Distinct types of AS/RS offer advantages in terms of storage density, throughput, SKU volume, and flexibility. They also vary in the container types, sizes and weights they can store and retrieve.

Types of AS/RS include –

1. Unit load AS/RS Systems store and retrieve pallet or container loads. A crane system travels in an aisle to lift and move goods. Unit load systems are ideal for heavy and bulky loads.
2. Mini-load AS/RS are for storing and retrieving smaller items, often in totes. They operate at high speeds to generate high throughput.
3. Mid-load AS/RS work with a mix of pallets and custom fixtures. These systems offer greater order profile flexibility and are smaller than unit load systems, but larger than mini-load systems.
4. Goods to Person Robots using robots to move shelves to a workstation is a popular AS/RS option. These systems offer excellent flexibility and can work with both low and high SKU volumes. The Go-fer Bot is a good example of this popular AS/RS type.
5. Cube Systems have shuttles that operate at the top of the cube and retrieve and store totes stacked in columns in the cube. The shuttles retrieve one tote at a time until they can access the needed tote. They are good for high density and very common SKU requirements, and they can achieve throughput by increasing the quantity of shuttles (until maximized).
6. Vertical Lift Modules (VLMs) are systems that move shelves or trays vertically. They offer dense storage in a small footprint. VLMs work well with smaller sized items, low SKU volumes, and moderate pick rates.
7. Horizontal Carousels rotate attached bins horizontally and operate in pods (groups) of 2-5 to provide higher picking rates. They provide dense storage and retrieval while reducing labor requirements.
8. Vertical Carousels rotate shelves vertically around a track and work in a small footprint. They are used where the storage footprint is limited, such as in a pharmacy or manufacturing location. Weight limitations and imbalanced loading need to always be considered.
9. Shuttle AS/RS Systems use robotic shuttles to transport goods to a workstation. They often travel within a storage grid or rack system. Lifts are often integrated to move robots with goods vertically in the system. These are ideal for high SKU volume and throughput. Common shuttle AS/RS types are –

1. 1. 1. Totes, case and tray handling shuttle AS/RS systems offer the flexibility to accommodate various types of small goods.
      2. Pallet Shuttle AS/RS Systems transport pallet loads. They are equipped with heavy duty motors for greater capacity.
      3. Stacker AMR Robotic Shuttles store and retrieve cases, totes and containers from rack or shelving system. These AMRs, such as the Stacker Bot, travels on the floor as an AMR but when in the proper position, use an inserter-extractor device to elevate and retrieve the required goods.

Newer AS/RS systems work with a broader range of SKU sizes, throughputs, and weights. These newer AS/RS solutions are better at integrating into your current infrastructure. They can integrate quickly into a WMS or WES with their own control software. They are also integrating with other automated material handling systems, such as conveyor systems and AMRs.

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Speak with a member of the Conveyco team.

Palletizer Automated Material Handling Systems

Palletizers are automated material handling systems that quickly stack cases onto pallets. Palletizers can manage a wide range of case types, sizes, and weights. Their in-feeds can be one-level or multi-level. They have a wide range of operation speeds, which are measured in cases per hour.

Types of palletizers include:

1. Robotic Palletizers use robotic arms equipped to grasp cartons and stack them in various arrangements. They are fully automated and manage a wide variety of weights and sizes. Robotic palletizing systems operate in a safe zone away from workers.
2. Conventional floor level palletizers use mechanical mechanisms such as conveyor to create layers of cases on pallets. These systems are ideal when case profiles are similar.
3. Overhead Gantry palletizers use overhead cranes and gantry systems that position and stack items onto pallets. These are often utilized for specific case types and goods and patterns.
4. Stack and Wrap Systems are automatic or semi-automatic systems that operate well with mixed, rainbow, and various case sizes. They are a two level structure with robots (automated) or humans (semi-automatic) placing conveyor delivered cases onto an active pallet always located at an ergonomic height. As the pallet layers are built, the pallet automatically moves down and an integrated stretch wrapper wraps each level as completed. The Stack and Wrap system can stack pallets higher than most systems because the cases are being wrapped one layer at a time. This system is ideal for reducing labor, floor space while increasing trucking density.

Current trends in palletizers include the integration of artificial intelligence (AI) to enhance flexibility and speed. Intelligent systems optimize stacking patterns based on product weight, size, location, and fragility. This reduces shipping costs and product damage risk during transport.

Pick-to-Light and Put-to-Light Systems

Pick-to-light systems use visual indicators, such as lights or displays, to guide warehouse workers. They identify the correct items and quantities needed to fulfill customer orders. Pick-to-light systems increase picking accuracy and picking productivity.

Put-to-light systems guide operators to the correct storage locations for placing items during replenishment or order consolidation. They also increase speed and accuracy.

Types of pick-to-light and put-to-light (PTL) systems include:

1. Automated Put Walls in an order consolidation process using pick and put-to-light. Items are scanned and inducted into the system. A robot or shuttle automatically places the items into a container, tote or gaylord. When all the items for that order are consolidated, lights will direct a picker or robot to retrieve the completed order and direct it to packing and shipping.
2. PTL displays can be mounted on racks and shelves to indicate which items to pick or put and in what quantity.
3. Cloud-based, wireless PTL systems are easily installed and operated. Ideal for smaller PTL system requirements. These are easier than hardwired systems, which require wiring and infrastructure changes.
4. Picking cart systems use mobile carts equipped with put-to-light displays. These allow operators to see the quantity to pick and to put items directly into a designated bin on the cart. These pick-to-cart systems can allow for efficient batch picking where multiple orders are picked simultaneously.

The growing trend is for pick-to-light systems to be seamlessly integrated with other warehouse automation technologies. Multi-color displays can be utilized to allow multiple operators to work in the same aisle simultaneously. Displays are being used to display the actual items.

Sortation Systems

Sortation systems automate the process of routing items to their designated destinations. This routing is based on supply chain criteria such as destination, shipping method, and order priority. Sortation systems help streamline order fulfillment processes, increase throughput, and improve accuracy by ensuring that items are directed to the right locations. The right type of sortation will be based on SKU size, weight, volume, profile, velocity, and destination.

Types of sortation systems include:

1. Automated Put Walls in an order consolidation process using pick and put-to-light. Items are scanned and inducted into the system. A robot or shuttle automatically places the items into a container, tote or gaylord. When all the items for that order are consolidated, lights will direct a picker or robot to retrieve the completed order and direct it to packing and shipping.
2. Cross-Belt Sorters use belts equipped with diverters to move items to designated chutes or lanes. This sorting type offers high-speed and high-capacity sorting capabilities.
3. Push-tray sorters feature trays that push items off the conveyor onto chutes or takeaway lines. They are suitable for efficiently handling a wide range of items.
4. Tilt Tray Sorters are an automated material handling system that uses a series of trays or carriers to move items along a track or rail. The trays can tilt or divert to the left or right at designated points, allowing the items to be sorted and routed to different destinations or collection points.
5. Bombay Sorters are also known as Flat Sorters. They are ideal for smaller items and excel at e-commerce. Bombay sorters sort directly into boxes for shipping.
6. Robotic sortation, such as the TiltSort Bot Sortation System is an extremely flexible system that can be used for omni-channel. By using AMRs to gather items, the system can meet the changing demands for a wide range of warehouse operations with small to medium-sized goods.
7. Shoe Sorters (and dual lane shoe sorters) use soft shoes or pads to gently and quickly divert parcels, boxes, or items to designated chutes and destinations based on the specified sorting requirements.

A trend with sortation systems includes the use of software to analyze real-time data such as order volume and order profiles. This optimizes the sorting process, reduces congestion, and improves overall efficiency.

Packaging Equipment

Packaging equipment automates the process of packaging products into containers, boxes, and pallets. These material handling systems make sure items are properly protected and secured for transportation.

Types of automated packaging equipment include:

1. Cartonization Systems use the dimensions, weights, and shipping methods associated with an order to determine the best carton size.
2. Dimensioner systems scan items automatically to determine the dimensions of a SKU to ensure a proper fit in packaging.
3. Carton erectors and formers automate the assembly of cardboard boxes or cartons from flat sheets of material.
4. Document Printers and Inserters can custom print personalized documents such as invoices, sales promotions, return labels, and more associated with each specific order and automatically insert them into outbound orders.
5. Dunnage inserters use lidar to calculate how much void needs to be filled prior to sealing. They will fill the package with items, like paper for safe shipping.
6. Case sealers automate the sealing of cardboard boxes or containers using adhesive tape or hot-melt glue.
7. In-motion weigh scales automatically weigh items prior to shipping.
8. Print and Apply Systems, also known as PANDA Systems, automate the application of shipping labels and documents to packages.
9. Palletizers come in a variety of types. Some are semi-automatic and others are fully automatic.
10. Stretch wrappers are used to wrap palletized loads with stretch film to secure and stabilize them for transportation.

Current trends in packaging equipment include the adoption of advanced technologies such as robotics and automation to improve packaging efficiency and flexibility. Robotic packaging systems utilize robotic arms equipped with grippers or suction cups to handle and package products with precision and speed.

Dock Systems

Dock systems stage and transfer goods between trucks, trailers, and containers and the warehouse. More automation is being introduced in this area. Popular dock automated material handling systems include pallet AMRs and auto loaders.

Types of automated dock equipment include:

1. Pallet AMRs can be used to transport pallets from staging areas to trucks. This can eliminate forklifts and relieves congestion on the dock while improving throughput and saving labor.
2. Automatic and semi-automatic autoloaders and unloaders are ideal for handling cases, totes, polybags, parcels, and various combinations of each. Trucks can be stacked or loose filled to improve truck density to save on transportation and labor costs. High volume systems use staging racks and telescopic conveyor to fill trucks with loose parcels, packages, and polybags.

• • Unmanned forklifts can load pallets onto trucks. These reduce the labor associated with driving fork trucks
  • Automatic truck loading systems (ATLS) stage complete truck shipments and move them into the truck using skates, wheels, rails and other devices.
  • The trend in docking is to reduce manual labor with automated equipment. This requires automated systems that are versatile to adapt to a variety of goods and transport types.

Robotic Picking Systems

Robotic picking systems enhance the order fulfillment process in warehouses and distribution centers by automating the picking of goods for customer orders. These material handling robots use advanced robotics, conveyor systems, and software to efficiently pick items from inventory and prepare them for shipment. This automated material handling (AMH) system can improve picking accuracy and reduce labor costs.

Types of automated picking systems include:

1. Goods-to-Person Systems where robotic shuttles or conveyors bring items directly to picking stations.
2. Robotic picking systems use robotic arms equipped with vision systems and grippers to identify, pick, and place items into order containers with speed and precision.
3. Autonomous Mobile Robots (AMR) systems come in a variety of manufacturers, models and styles. By analyzing your inventory characteristics, order profiles, facility layout and characteristics, customer expectations (and more), we create the RightFIT AMR system to meet and exceed your operational and business goals.
4. Automated storage and retrieval systems (AS/RS) integrate picking functionality into their design, allowing for automated storage and retrieval of goods as part of the picking process.

The current trend with warehouse robotics is with a focus on AI for vision. Using self-learning with vision systems, robotics can learn to pick assorted items and orientations. This increases their speed and versatility.

Carton Flow Systems

Carton flow systems are material handling solutions that move goods for picking. These systems often use inclined rollers or conveyors that allow cartons to move from one end to another. Carton flow systems help improve picking efficiency as the goods are moved to the pick station.

Common types of carton flow systems are –

1. Shelving systems set at an incline allow cartons to move into the pick zone. As the cartons are removed, a new carton presents itself for picking.
2. Rack systems work with larger goods. They move goods such as pallets to a case picking zone.
3. Conveyor systems use motorized belts and rollers to advance goods of all types to pickers. These can be advanced manually by operators or automated.
4. Goods-to-Person Picking AMRs use AMRs to carry goods to the picking workstation. The AMRs create a continuous flow or lines of goods at the picking workstation to provide accuracy, high speed, and ergonomic operator activity.

The popularity of Goods-to-Person AMRs (GTP AMRs) is increasing. As a carton flow system, AMRs are very flexible and can operate in dynamic warehouse environments. They can easily retrieve goods from many areas of the warehouse. AMRs easily assist with load management.

RFID and RF Scanning Systems

RFID (Radio Frequency Identification) tag systems and RF (Radio Frequency) scanning systems help with logistics, inventory tracking, and asset management. RFID systems use radio frequency signals to wirelessly identify and track tagged items.

RF scanning systems capture data from RFID tags and barcode labels and wirelessly transmit data to the host WMS, ERP or WES software systems. These automation systems provide quick, efficient real-time visibility of items.

Types of RFID Tag Systems are:

1. Passive RFID systems use RFID tags powered by RF signal emitted by RFID readers. These do not require a battery, making them suitable for tracking items over short distances.
2. Active RFID systems use battery-powered RFID tags that transmit signals independently, enabling longer-range tracking and monitoring of assets across larger areas.

Types of RF Scanning Systems are –

1. Personal RF scanning systems such as handheld scanners are very popular.
2. Wearable scanners such as wrist-based scanners allow for hands-free operation.
3. Scan tunnels allow for high speed scanning using multiple scan points to identify goods quickly in processes such as a distribution center sortation process.

Current trends in RFID and RF scanning systems include the integration of cloud-based software platforms and IoT (Internet of Things) connectivity for real-time data analytics, predictive maintenance, and supply chain optimization.

Automated Material Handling System Software

Material Handling Software is becoming more vital as warehouses automate and become more digital. Warehouse software plays a key role in coordinating the various automated systems and processes within warehouses and distribution centers. Material handling software helps automate and streamline key warehouse operations to improve operational costs. It improves order processing, inventory tracking, storage, picking, sortation, consolidation, packing, and shipping.

Types of material handling software are:

1. Enterprise Resource Planning Systems (ERP) are business software systems that operate many parts of the business. ERP systems track warehouse inventory, orders, and order processing.
2. Warehouse Management Systems (WMS) work with Enterprise Resource Planning Systems (ERP) to provide more detailed control over warehouse operations.
3. Warehouse Control System (WCS) is a type of software that controls automated material handling systems. WCS provides the control and functionality needed for automation to work within a warehouse.
4. Warehouse Execution Systems (WES) is an integrated system that optimizes the entire fulfillment operation. It improves the warehouse management and the orchestration of inventory, labor, order, automation, and shipping processes. WES eliminates automated WCS islands in a facility and orchestrates an entire facility’s inventory and labor to enhance performance and eliminating islands of automation.

One current trend with material handling software is to provide dashboards and reporting tools to enable warehouse managers to analyze key performance metrics. This identifies areas for improvement to make data-driven decisions to optimize warehouse operations. Newer WES platforms excel at integration of various automated systems and prevent disconnected islands of automation.

Automated Material Handling System Selection and Integration

Each of these twelve automated material handling systems have various types and technology trends. Determining the right material handling solution for warehouse automation is complex. System integrators, such as Conveyco, assist warehouse and distribution managers in determining the best combination of automated material handling systems for businesses. Conveyco’s RightFIT methodology uses a proven seven step process to ensure your automation project’s success. Schedule a free consultation with one of our experts here about these material handling systems and more.