Automation

The High Bay Warehouse Automation System:
Streamlining Your Business Operations.

Jacob Abraham, Bran Systems

plant automation manager

Introduction

The High Bay Warehouse Automation System revolutionizes the movement of products from various sources within your manufacturing facility. It leverages Automated Stacker Cranes and Automatic Guided Vehicles (AGVs) to efficiently transport products to and from individual storage locations in the High Bay Warehouse. By optimizing the system of product put away and order fulfilment, businesses can experience a significant boost in operational efficiency.

automated car plant

Implementing an end-to-end solution for managing and controlling a shuffle and sort buffer or warehouse presents several challenges. The High Bay Warehouse Automation System addresses these challenges effectively:

 

  1. Fully Integrated Solution: Finding a fully integrated solution that seamlessly manages and controls a shuffle and sort buffer or warehouse can be a daunting task. The High Bay Warehouse Automation System provides a comprehensive solution that covers all aspects of warehouse management and control.
  2. Adaptable to Existing or New Warehouses: Whether you need to accommodate existing warehouse and production flows or design and integrate a new warehouse and routing system, the High Bay Warehouse Automation System offers the flexibility to adapt to your specific requirements.
  3. Real-time Production Requirements: To meet the dynamic demands of real-time production, it is crucial to supply products when and where they are needed based on downstream demand and upstream supply considerations. The High Bay Warehouse Automation System seamlessly integrates with your organization’s ERP, product tracking, and scheduling systems to ensure timely product delivery.
  4. Throughput Maximization and Cost Reduction: Maximizing throughput while minimizing maintenance and energy costs is a key objective for any warehouse operation. The High Bay Warehouse Automation System optimizes crane movements and provides high throughput rates, resulting in increased operational efficiency and reduced costs.
  5. User-friendly Environment: Operating in a user-friendly environment is vital for efficient production control and maintenance. The High Bay Warehouse Automation System offers a graphical interface that provides full visibility of the facility, enabling easy production control and maintenance operations.
  6. Business Intelligence and Reporting: Delivering business intelligence and flexible reporting capabilities to management is essential for informed decision-making. The High Bay Warehouse Automation System offers comprehensive management reporting functionalities, empowering businesses with valuable insights.

Technical Information

The High Bay Warehouse Automation System incorporates a range of technical components to ensure its smooth operation:

  • Oracle 11g Failsafe Cluster configuration
  • MS Windows Server 2003 Enterprise R2
  • HP DL380 Cluster configuration, EMC AXA storage
  • C#.Net Framework 3.5 Rules Engine
  • Visual Basic.NET Framework 3.5 front-end
  • Archestra System Platform 2014 and Intouch 2014 SCADA
  • Various PLCs: Siemens S7400, S7300, S5; Allen Bradley Compact Logix, AEG A250

These technical components work together to provide a robust and reliable system that can handle the demands of high-value product storage and order fulfillment.

trucks

Customer Benefits

Implementing the High Bay Warehouse Automation System offers numerous benefits for businesses:

 

  • Shuffle and Sort Facility:
    The system provides a shuffle and sort facility for high-value products, allowing for efficient organization and retrieval.
  • Production Process Control:
    Businesses can enjoy flexible management, scheduling, and control of the production process, leading to increased productivity and operational efficiency.
  • Automation and User-Friendliness:
    The High Bay Warehouse Automation System is highly automated and offers a user-friendly interface, simplifying warehouse operations and reducing the margin for error.
  • High Throughput Rates:
    By optimizing crane movements and product sequencing, the system ensures high throughput rates, maximizing operational efficiency.
  • Vehicle Manufacturing Context:
    In a vehicle manufacturing context, the system controls the movement of skids, body in white, EC coated and painted bodies through the warehouse, catering to different types of racking stores and optimizing the flow of products between different production stages.

Key Feature

The High Bay Warehouse Automation System encompasses several key features that enhance its performance and functionality:

 

  • Warehouse Optimization:
    The system includes stacker cranes, conveyors, entrance and exit areas, as well as warehouse bypass routing to optimize the flow of products within the facility.
  • Integration with PLCs:
    The High Bay Warehouse Automation System seamlessly integrates with multiple programmable logic controllers (PLCs) that control the cranes and conveyors, allowing for easy integration into most existing plants.
  • Dynamic Hold and Release Facility:
    A comprehensive multiple dynamic hold and release facility ensures efficient storage and retrieval of products, including the capability for partial releases.
  • High Throughput Rates:
    By optimizing crane movements and product sequencing, the system ensures high throughput rates, maximizing operational efficiency.
  • Product Sequencing:
    The system enables complex product sequencing to feed various assembly lines. It employs sophisticated algorithms to optimize color/model batching, model category line balancing, and maintain fixed minimum and maximum ratios of product categories supplied to assembly lines.
  • Crane Cycle Optimization:
    Optimizing crane cycles is crucial for reducing wear and tear and increasing throughput. The system achieves this by picking up products after drop-off, dropping off items in the closest compartment to the drop-off point, and bypassing products around the High Bay Warehouse when possible.
  • Effective Communication:
    The High Bay Warehouse Automation System seamlessly communicates with corporate scheduling and product tracking systems, ensuring accurate and real-time information exchange.
  • Barcode and RFID Tracking:
    By capturing and tracking products using barcodes or RFID at various entry points, the system enables precise product monitoring and management in conjunction with corporate tracking systems. It also features separate entrance and exit sorting and dispatch areas for enhanced efficiency.

Conclusion

The High Bay Warehouse Automation System is a game-changer for businesses aiming to optimize their manufacturing operations. By streamlining product flow, enhancing order fulfillment, and providing a user-friendly environment, this system offers significant advantages, including increased throughput, improved efficiency, and cost reduction. Incorporating the High Bay Warehouse Automation System into your business can drive productivity and elevate your competitive edge.

If you are a business looking to implement High bay warehouse automation, Bran Systems IT and Automation Systems provide cost-effective and dedicated client-oriented services and solutions for businesses seeking to implement High bay warehouse automation. With our technical expertise and knowledge, we can assist you in achieving your automation goals.

Download Brochure

For Further Information About The High Bay Warehouse Automation System Contact One of Our Experts

ERP

ERP Solutions from SAP Business 1

 

Automation

Design, Development & Fabrication

 

Software

Packaged & Bespoke Software Solutions

 

Schedule a Meeting

5 + 3 =

Bran Systems

6 Slater Street
North End, Port Elizabeth, 6000

041 582 1140

sales@bransystems.co.za

Mon-Fri: 8am – 4:30pm
Sat-Sun: Closed