Digital Transformation of Warehouse Processes

Revolution in Data Collection

The digital transformation of warehouse processes in intralogistics involves adapting modern digital technologies to streamline and automate internal logistics operations and warehouse management. By implementing warehouse management systems (WMS), automation using robots, integrating the Internet of Things (IoT) for inventory monitoring, and data analysis, companies can respond more quickly to changing market conditions and customer needs. This enables better inventory management, reduced order fulfillment time, and improved customer service quality.

Automation and robotics can revolutionize the way your company collects and processes data. Whether your organization is just beginning its journey with technology or already implementing innovative solutions, it’s important to understand the benefits of integrating modern systems. Automation and robotics not only increase efficiency but also allow for better resource management and improved quality of production and distribution.

Internet of Things (IoT)

The Internet of Things (IoT), in the context of industry, also known as Industrial IoT (IIoT), refers to a network of interconnected devices, machines, sensors, and systems that communicate with each other and exchange data in real-time. In industry, IoT enables remote monitoring and control of production processes, as well as more efficient and automated resource management.

IoT: Real-Time Monitoring

IoT devices can continuously track machine operating parameters, inventory levels, energy consumption, and other key indicators, allowing for quicker responses to any irregularities.

IoT: Predictive Maintenence

By analyzing data from IoT sensors, it is possible to predict and prevent failures before they occur, reducing downtime and repair costs.

IoT: Process Optimization

Collecting and analyzing large amounts of data enables better understanding and optimization of production processes, leading to increased efficiency and waste reduction.

IoT: Increasing Operational Efficiency

IoT enables the automation of many tasks, speeding up operations and reducing the risk of human errors.

IoT: Better Resource Management

Thanks to IoT, it is possible to track the location and status of resources in real-time, facilitating warehouse management and logistics.

IoT: Improving Safety

IoT systems can monitor working conditions and the status of machines, helping to identify potential hazards and prevent accidents.

System Integration

System integration is the foundation of effective data management in intralogistics. By supporting PLC controllers and integrating with MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), and WMS (Warehouse Management System), it is possible to create a cohesive work environment. These systems automate and optimize key operations, ensuring data accuracy and consistency throughout the organization. IoT and cloud options enable remote access and real-time monitoring, which is crucial for quick responses to changing production and logistics conditions.

MES (Manufacturing Execution System)

Manufacturing Execution System (MES) is software that monitors, controls, and optimizes production processes in real-time. It enables the collection of data from machines and production lines, allowing for precise performance analysis and problem identification. MES helps manage production, track product lifecycle, and ensure high quality and efficiency in production operations.

ERP (Enterprise Resource Planning)

Enterprise Resource Planning (ERP) is integrated software for managing all key business processes in an organization, such as finance, human resources, production, sales, and logistics. An ERP system provides a single, central database that facilitates the flow of information between different departments within the company, increasing efficiency and accuracy in operations. With ERP, companies can better plan and manage their resources, improving both operational and strategic decisions.

WMS (Warehouse Management System)

Warehouse Management System (WMS) is specialized software for managing warehouse operations, such as receiving goods, storage, order picking, and shipping. WMS helps optimize the use of warehouse space, automates processes related to the flow of goods, and increases the accuracy of inventory management. This system enables companies to improve the efficiency of warehouse operations, reduce order fulfillment times, and lower operational costs.

Data Collection and Production Monitoring

Data collection is crucial for tracking internal logistics processes. Information about cycles and processes, operator work, downtimes, workstation efficiency, alarms, and events allows for complete control over the entire production and logistics process. Monitoring production parameters, such as cycle time, production rate, number of units produced, and number of rejects, enables efficiency analysis and the identification of bottlenecks and downtimes. This allows for quick responses and the implementation of changes, leading to the optimization of production and logistics processes.

Key Performance Indicators – KPI

Monitoring KPI includes operator work efficiency, work optimization, and alignment with the production line and average work times. Key indicators that can be monitored include:

OEE (Overall Equipment Effectiveness)
Average cycle times
Number of downtimes and their duration
Raw material consumption efficiency
Quality indicators

Sustainable Resource Utilization

Media monitoring enables real-time tracking of electricity, water, and gas consumption in internal processes, leading to savings and an ecological approach to resource management. Constant control of resource consumption allows for the identification of areas where savings are possible and the implementation of more efficient resource management methods.

Reporting and Analysis

Reporting allows for the creation of detailed historical reports, data export to CSV format, and customization of reports to meet individual user needs. Regular reporting enables systematic progress monitoring, trend analysis, and the identification of areas needing improvement.