Managing Storage

Minimizing errors and optimizing space and manpower have been challenging for some warehouse managers, particularly in the cold environment. Fabio Fornaciari, system engineering director of Elettric 80 AB, shares with Asia Food Journal on making some wise moves for a better warehouse environment.

By automating a cold chain warehouse, operators are not constantly exposed to the harsh environment and managers are assured of safety.

AFJ: What automation systems can a F&B warehouse implement?

Fornaciari: The solutions that are needed for warehouses depend on some principal parameters such as the number of stock keeping units (SKUs), the maximum length of batch of production, the unit load or pallet type (stackable or otherwise) and shipping requirements (cross docking or storing the goods in the warehouses for days or weeks before shipping).

Depending on these variables, there are solutions for floor storage warehouses, where the pallets are stacked on top of one another (in fast movement warehouses); selective rack warehouses, where the pallets are placed in dedicated rack locations (in selective warehouses); drive-in-rack warehouses and flow rack warehouses (high density warehouses).

With our laser-guided vehicle (LGV) for example, operators can bring two pallets per trip at 19 ft high. It can also bring one pallet per trip at 36 ft high. These solutions can be handled by an intelligent software called a warehouse optimizer (WO), which can interface with common enterprise resource planning (ERP) systems for optimal LGV missions and greater warehouse operational efficiency.

AFJ: How can companies enjoy their returns of investment upon automating their warehouses?

Fornaciari: Our customers have increased the number of pallets shipped per day as a result of optimized pallet movement. They are also seeing reduced operational costs due to the low maintenance of the LGVs. There is greater data safety as a result of real-time knowledge of pallet locations in warehouses, a better use of space and reduced manpower costs and fewer accidents. The damage to products is also minimized thanks to precision handling.

Operational costs are reduced due to the low maintenance of the laser-guided vehicles.

AFJ: How is safety part of warehouse automation?

Fornaciari: The LGVs are equipped with safety components that comply with global safety regulations such as Europe’s Conformité Européenne (CE) and the US Occupational Safety and Health Administration (OSHA). The safety components and the software that regulates the LGV traffic in warehouses allow fast movement without affecting product stability and the safety of the operators. Real-time tracking data collected by the software, including those belonging to pallets that have been shipped, are stored in a database, providing managers with traceable information.

Elettric 80 AB’s customers have increased the number of pallets shipped per day as a result of optimized pallet movement.

AFJ: How are the needs of a cold chain warehouse different from a typical one?

Fornaciari: From our experience, installations have been successful due to the specific requirements needed in the -25°C environment, particularly laser sensors for navigation and battery changeover. This brings greater efficiency beyond manual operations that would typically consist of four shifts of six hours daily. By automating a cold chain warehouse, operators are not constantly exposed to the harsh environment and managers are assured of safety, optimal data tracking and warehouse efficiency.

Fabio Fornaciari, system engineering director of Elettric 80 AB.

AFJ: How are operators trained to handle automated systems?

Fornaciari: It is important to work with and train our customers on a regular basis, which usually comprises of a team of supervisors from the information technology, production and logistic departments from the warehouse. The team will have access to our project managers, site managers and trainers from our local subsidiaries as they can speak the local language and understand the local culture.

AFJ: How is an error-free, automated warehouse environment possible?

Fornaciari: In order to get the most out of an automation system, one needs to consider two things. Firstly, the areas that are automated must be served by the systems only. There should be no uncontrolled manual interference in order to prevent inconsistencies between the physical status of the goods and the systems’ perceived status of them. Managers are assured that the LGVs will react to any packaging material, pallets or other items detected in its way, and the vehicles will stop when the goods are moved. Secondly, operational activities must be planned and registered within reasonable expectation. Orders should be generated and missions should be carried out based on clear priorities. Round-theclock shipments can be prepared as long as the orders are entered in the system in a timely manner.