Is There Still a Place for the Humble Conveyor in the Modern Warehouse?

  • Jul 17, 2024
  • U.S.
Choosing the Ideal Warehouse Automation System for Pallet Storage Andrey Kras Intralogistics Division Daifuku

The material handling industry is experiencing an influx of new and exciting technologies that often promise to revolutionize the modern warehouse. As warehouse professionals, it is up to us to determine which technologies can meet our business objectives.

The industry has experienced various technological developments over the decades, with some becoming popular and others fading away. In recent years, Autonomous Mobile Robots (AMR’s) and AGV’s have surged into the marketplace. This technology can broaden the application of automated systems and may overlap the application of traditional technologies. This overlap may have us asking, how do conventional technologies like conveyors still provide value within the modern warehouse.

This article will explore how AMRs compare to conveyors, the more traditional warehouse automation.

Assessing the viability of conveyors in warehouse automation: is it still a viable solution?

Throughout history, humans have consistently devised innovative ways to transport goods from one location to another. Conveyors have been used in some form for more than 230 years.

Things really started to pick up during the industrial revolution with Henry Ford famously using conveyors to boost productivity on his assembly lines. Today modern conveyors have evolved into the workhorse of the modern intralogistics supply chain. The evolution of conveyor systems serves as a testament to our ingenuity and our desire and need to move massive amounts of goods throughout our society. Modern conveyors can move materials as small as a single grain of rice to massive amounts of earth and rock in the mining industry.

Advantages

In intralogistics, conveyors can handle various package types including polybags, cartons, totes, trash, etc. Conveyors have evolved from simply transporting materials to providing sortation to support business processes. One major advantage of conveyor is the variety of modules that have been developed, and the staggering amount of research and development that has been devoted over the past 100 years. Even today, conveyor is still reliable, fast, and well established in the material handling industry.

Hence, the ability of a conveyor system to reliably connect the different parts and areas of a modern warehouse is unparalleled. These systems can provide more throughput and routing packages more reliably to more operations than any other technology.

Disadvantages

Although, conveyors do not come without restrictions, some of the biggest drawbacks to a conveyor-based solution is space and flexibility. The conveyor and all support structures required to keep it in place can eat up space quickly. Even more so with the space that it consumes, conveyor is bolted in place and the layout becomes fixed. New flows or processes may require significant effort, which can be challenging in a dynamic material handling environment.

Let us take a closer look at AMRs to see how they provide a new perspective on the industry.

Expanding the reach of automated transportation and sortation with autonomous mobile robots (AMRs)

Autonomous mobile robots, commonly known as an AMRs, are highly advanced robots that can navigate their surroundings and handle tasks without the need for human intervention.

Advantages

Unlike more traditional Automated Guided Vehicles (AGVs), AMRs do not require pre-defined tracks. Instead, they use a combination of real-time sensors, mapping technologies such as Simultaneous Localization and Mapping (SLAM), and Artificial Intelligence (AI) to move around a facility in a more dynamic and flexible way. By using these advanced technologies, AMRs expand the possible applications for automation and bring significant benefits to various industries.

One of the biggest advantages of an AMR system over a traditional conveyor solution is flexibility. AMRs do not require tracks or large amounts of fixed equipment. An AMR can move freely through a large open space, allowing customers to move products throughout the building fewer restrictions on space. AMR’s can also interact in space with people. No need for safety fencing or fixed travel paths.

Another key benefit of an AMR system is scalability. With an AMR system you can start with a single robot and simply add additional robots to increase productivity. This allows customers to get into a system with a lower entry cost, which makes it an ideal choice for small and mid-sized businesses that want to automate their operations without breaking the bank.

Disadvantages

Like any technologies, there are limitations to AMRs and how they can be implemented. One disadvantage is instant speed. While you can scale a system with multiple robots, there is a limit to how much volume can be taken away or delivered to a specific point. Another concern is how new some of the features are in some of these systems. While AMRs have shown in recent years that they are a proven and reliable solution, in many cases we do not always have examples of specific case studies for a particular solution. Often customers may feel they are truly getting into cutting edge technology developments with the experience of iterative testing.

AMRs do have an ongoing cost beyond the initial purchase price. Lucas Systems estimates that the annual cost for maintenance for an AMR is 20% of the capital cost. Batteries will need to be replaced around the five-year mark, and that is a significant cost depending on the fleet's size. There are other costs to be considered such as software updates, system reconfigurations, and training.

Finding the right balance: traditional vs. modern technologies in warehousing

In conclusion, when comparing traditional conveyor systems to autonomous mobile robots (AMRs) it's important to consider the specific needs and objectives of your warehouse operations. While traditional conveyors offer reliability and efficiency for certain applications, AMRs provide flexibility and adaptability to dynamic warehouse environments. Ultimately, a hybrid approach that combines the strengths of both technologies may offer the most comprehensive solution for optimizing productivity and efficiency in warehouse operations.

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By integrating these advancements, you can stay up-to-date and improve your warehouse operations while keeping your business running smoothly. Finding the right material handling solutions can significantly improve the efficiency of your warehouse operations.

At Daifuku Intralogistics America, we offer a wide range of products and technologies that can be combined to create advanced systems tailored to your business needs. We are committed to helping you achieve next-generation warehouse solutions that can drive growth and success for your business.

Giovanni Stone

Andrey Kras

Senior Vice President, Daifuku Intralogistics America
Giovanni Stone has worked for Daifuku Intralogistics America for more than 15 years, and during this time, he has earned a reputation as an exceptional problem-solver and leader. He is committed to excellence and has consistently helped his team perform at their best.

As a key figure in the company, Giovanni aligns Daifuku's sales and product strategy with its core assets: its people, processes, and technology. He is meticulous in his approach and uses his insight to ensure that the company not only meets but exceeds its targets. He is focused on maximizing stakeholder value and driving profitable growth.

As the Senior Vice President, Giovanni continues to build on his impressive track record in advanced automation execution. He brings a fresh perspective to Daifuku's sales positioning, identifying market opportunities, creating tangible business value, and orchestrating seamless expansions.

Giovanni's visionary outlook benefits Daifuku's clients directly. He is versatile, collaborates cross-functionally, and has an extensive professional network, all of which enhance their experience. He is a catalyst for positive change and is focused on informed decision-making, organizational excellence, and fostering a winning culture to ensure that Daifuku remains at the forefront of innovation.

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