Businesses face immense pressure to deliver products quickly, accurately, and affordably. As the global supply chain grows more complex, fulfillment centers use new technology to meet these high demands.
Fulfillment automation streamlines the fulfillment process from start to finish, efficiently moving products from the production line to the customer. This article discusses what a fully automated fulfillment process looks like and how automation benefits fulfillment centers.
Defining Fulfillment Automation
Fulfillment automation uses technology to perform tasks traditionally handled by humans in warehouse operations. Automation completes tasks like picking, sorting, and packing products through software and robotics. Using robots for these tasks accomplishes them faster and with fewer errors than human workers.
Automation does not mean replacing human workers. This technology is designed to work alongside humans, improving the efficiency and accuracy of repetitive and time-consuming tasks. Employees are then free to focus on value-added tasks.
The rise of same-day and next-day shipping has resulted in an all-time high demand for faster delivery. Automation addresses this challenge by:
- Increasing Speed: Robots work continuously without a break, resulting in faster throughput.
- Improving Accuracy: Robots use advanced sensors to correctly select items, resulting in more accurate packing and shipping.
- Reducing Costs: Though traditional automation requires an up-front investment, it results in long-term savings.
Automation Found in a Fully Automated Fulfillment Process
A fully automated fulfillment process uses several connected systems. These systems manage inventory, process orders, and prepare shipments.
- Automated Picking Systems
Picking is one of the most labor-intensive tasks in a warehouse. Systems such as robotic picking and palletizing arms streamline the picking process and improve speed from order to pick, which in a high-volume setting can compound and cause massive delays if not done efficiently. - 4-Way Shuttles & Automated Storage and Retrieval Systems (AS/RS)
A 4-way shuttle and AS/RS are designed to store and retrieve inventory efficiently. AS/RS, like vertical carousels or shuttle systems, maximize space and provide quick access to products. Warehouses can store more inventory in less space and retrieve items faster than manual labor with an AS/RS. - Autonomous Mobile Robots (AMRs)
AMRs are robots that move through the warehouse to transport goods. Unlike conveyor belts, AMRs can move freely through the warehouse without the need for pre-designed paths. Advanced sensors allow AMRs to avoid obstacles and navigate the warehouse in the shortest routes, saving time and energy. AMRs’ flexibility makes them one of the most beneficial tools a warehouse can invest in.
Benefits of Fulfillment Automation
- Improved Efficiency
Automated systems work faster and more consistently than humans since they do not need regular breaks. Robots can process significantly more orders in a period than humans can, which is especially beneficial during peak seasons. - Greater Accuracy
Automation reduces human error in tasks like picking, packing, and labeling. Robotics ensure the correct items are retrieved and packed for every order, resulting in fewer returns and higher customer satisfaction. - Lowered Costs
Though traditional automation requires an up-front investment, the long-term savings are substantial. Automation lowers operational costs and optimizes the use of space and materials. Many automated systems also minimize energy consumption, which reduces utility costs. - Long-Term Scalability
Warehouses can scale operations to meet growing demands with automation. Robotics can handle increases in volume without compromising performance. During peak seasons or times of growth, automation keeps warehouses prepared. - Better Use of Human Resources
By automating repetitive and labor-intensive tasks, warehouses allow employees to focus on more critical tasks like customer service or equipment maintenance. This shift ultimately improves workplace satisfaction since employees can contribute more meaningfully.
The Workflow of a Fully Automated Fulfillment Process
- Receiving Inventory
Automated systems handle the unloading process when products arrive at the warehouse. Conveyor belts, robotic arms, or AMRs move products from delivery trucks into the facility. Inventory is then scanned and cataloged using advanced RFID technology to log each item into the WMS in real-time. - Storage
Once inventory is logged, an AS/RS places items in specific locations. These systems use 4-way shuttles, vertical lifts, or carousels to move goods within the racking system. The robotic system determines the optimal storage location based on demand frequency and size for quick access when the item is needed. - Order Picking
When a customer places an order, the fulfillment process begins automatically. Shuttles and AMRs retrieve the required items from storage. Then, AMRs transport these items to picking stations. - Picking, Packing, and Labeling
At the pick station, automated systems sort the items into pallets, totes, or cases. Full pallets may be automatically wrapped, or totes and cases packaged to reduce waste and shipping costs. Labels are printed and applied automatically to prepare the item for shipment without error or delay. - Shipping
Conveyor systems or AMRs transport the packed orders to the shipping area. Orders are sorted based on destination and loaded onto the delivery trucks using automated loading systems. The WMS tracks each step to ensure seamless fulfillment.
Final Thoughts
Completely automated fulfillment centers are becoming more common. Automation helps warehouses achieve maximum efficiency and accuracy, improving operations overall. With the right strategy and partner, implementing automation is one of the wisest choices a business can make to set itself up for long-term success.
Reach out today to learn more about how to partner with Prime to automate your fulfillment center.
