Breaking down the automation cost barriers

Breaking down the automation cost barriers

With the introduction of its RackBot™ system Rainbow Dynamics has broken through the cost barriers that have prevented many SMEs from introducing automated mini-load tote picking systems in the pastsays Frazer Watson, Global Vice President of Rainbow Dynamics

Picking customer orders is among the least cost-efficient of all the processes that are undertaken within a busy warehouse. In fact, some warehouse managers will readily admit that the task accounts for over 50 per cent of their operating expenses.

There are numerous reasons for this but the most obvious has always been that order picking can be very labour intensive and, even before the current spiralling employment costs started giving logistics managers sleepless nights – the payroll has   represented a warehouse’s single biggest operational overhead.

But the emergence of better automated storage and retrieval technology means companies are now not only able to cut the cost of order picking by reducing the number of workers dedicated to the process but can also enjoy a host of other benefits such as significantly improved use of warehouse space and enhanced picking efficiency, greater inventory capacity, fewer picking errors and reduced stock damage.

Which is why more and more warehouse operators are opting to automate aspects of the order picking process.

Of course, there are numerous products and technologies available that allow full or partial automation of a specific task, but Mini-Load Automated Storage and Retrieval Systems (ASRS) stand out as one of the best ways of enhancing the small parts picking process.

Mini-loads use small cartons and trays to store inventory and deliver picked stock to workers, so members of the picking team are no longer required to walk around the warehouse retrieving the items on their picklists themselves.

Offering speed, accuracy, and space efficiency, they are ideal for applications where high-speed picking and efficient storage of small items is required and where rapid retrieval and precise handling are critical.

However, like all types of AS/RS, a Mini-Load’s initial set-up costs can be substantial, particularly for facilities requiring custom configurations such as the installation of a suitable racking structure.

As a result, this valuable technology has been out of reach for many small and medium-sized warehouse operations.

But with the introduction of RackBot™ AS/RS Rainbow Dynamics has broken through the cost barriers that have prevented companies from introducing automated mini-load tote picking systems in the past.

The RackBot™ system is designed to handle the fast throughput requirements of the pharmaceutical, health and beauty, electronics, manufacturing, and automotive sectors and is particularly suited to the demands of modern e-commerce and micro fulfilment centres.

Capable of operating at up to 8 metres high, RackBot’s™ clever design and straightforward build process mean it is no longer necessary to replace a site’s existing racking scheme: RackBot™ runs on rails that are attached to whatever storage system is already in place. 

And while other systems on the market often require super-flat flooring, which can add significantly to the project’s total costs, RackBot™ operates at full capacity on any standard warehouse surface.

Importantly, unlike some high density mini-loads that require a bespoke design for each project – and usually come with a hefty price tag as a result – RackBot™ uses standard modular componentry. This means that RackBot™ solutions are not only straightforward to plan but also quick to install. In fact, RackBot™ is typically up and running in around one-third of the time that it takes to build similar schemes that use other technology. Furthermore, comparisons with other manufacturers’ prices, show typical installation costs are halved with RackBot™.

Automated goods-to-person picking solutions have a key role to play in modern warehousing and order fulfilment operations. And the availability of highly cost-effective, versatile and easy-to-install systems such as Rainbow Dynamics’ RackBot™ means the technology is now in reach of the companies who have the most to gain from it – which could have the biggest impact on supply chain operations since the invention of the pallet!

Russell Field

Russell Field is Managing Director of a contemporary marketing agency with clients in the haulage, distribution, freight and logistics industries. Russell holds a BSc (Hons) in Marketing and specialises in digital marketing and research.

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