How to optimise your warehouse system
The automation of storage processes is made possible by the high-tech equipment that is warehouse stacker cranes. Despite the high initial cost, many companies opt for this investment because of the long-term benefits. These systems eliminate the need for manual work, which reduces the risk of errors and accidents and lowers operating costs.
The profitability of the investment depends on the fulfilment of certain conditions, such as appropriate parameters for the flow of goods, the amount of products to be stored and optimal planning of the warehouse dimensions. The correct correlation of length, width and height of the storage space plays an important role. The stacker crane system should be individually adapted to the needs of the company, allowing it to optimise storage processes and return on investment.
Precision storage without operators
The warehouse stacker crane is an automated device that is part of a storage system and is designed to move and place loads on shelves. It is equipped with motors for vertical and horizontal movements, a gripping mechanism and a set of sensors to improve precision.
The crane is controlled via an intelligent warehouse management system (WMS), eliminating the need for a WJO-certified operator. The implementation of stacker cranes allows for optimal racking layout and maximum utilisation of warehouse space, replacing traditional solutions requiring forklifts and personnel. This makes it possible to increase storage capacity and improve the operational efficiency of the warehouse.
Automated stacker cranes - benefits
Stacker cranes are a modern solution that significantly improves the quality of warehouse operations. Before deciding to invest in such a system, it is advisable to familiarise yourself with its advantages. The main benefits include a high level of safety for the goods, as the system is fully automated, eliminating the need for operators. The stacker cranes also make better use of the available warehouse space, thanks to their ability to work in narrow aisles and at great heights. In addition, the WMS system that works with these cranes monitors stock levels in real time, allowing the assortment to be tracked in real time and shortages to be addressed. The equipment is also characterised by low energy consumption, as the energy regenerators recover electricity when the load is lowered. Thanks to these features, the system operates efficiently around the clock.
Types of stacker cranes in warehouses
Different types of stacker cranes are available to suit the specific needs of a warehouse. Their classification is based on two criteria: the control method and the design. In the first classification we distinguish between manually controlled and automated stacker cranes. The second classification is between column and frame stacker cranes. The storage systems that use these types of cranes can be classified as follows:
- systems with stacker cranes and Pallet Shuttle,
- systems with different storage depths,
- systems with three-sided stacker cranes.
In systems with stacker cranes and Pallet Shuttle trucks, it is the trucks that move in the racking aisles, transporting the pallets between the racking and the crane. This solution allows optimum use of storage space. In systems with varying storage depths, a single arrangement is used as standard. More advanced configurations, with depths of up to four levels, require the use of telescopic handlers or forks. If we are talking about systems with three-sided stacker cranes, here the stacker cranes have a rotating head that allows movement in three directions. This allows them to place loads both laterally and frontally.
What are the modes of operation?
Warehouse stacker cranes can operate in different modes, depending on the needs of the company in question. In manual mode, the unit is operated by an operator inside the cabin, which is particularly useful for servicing and maintenance. The crane is controlled by a panel located inside the cabin.
The automatic mode allows the stacker crane to work without human intervention, carrying out the tasks assigned by the warehouse management system, which optimises the sequence of operations, making the storage and retrieval process more efficient. This allows the stacker crane to work continuously, achieving maximum efficiency.
There is also a semi-automatic mode, which is used in specific cases where access to a specific load is required. The operator then uses a computer located at the end of the working aisle to give specific commands to the crane. Thanks to the variety of operating modes, the stacker cranes can be flexibly adapted to the operational and technical requirements of a specific warehouse.
Implementing stacker cranes - what to consider
When investing in these crane systems, there are several important factors to consider. First of all, it is a good idea to check whether the stacker cranes have already been implemented in our industry, especially when storing similar products or in similar distribution conditions. Such experiences allow us to avoid potential problems and better plan the implementation. Another aspect is to analyse the location, which should be suitable for installing the stacker crane. It is important to check that there are no height restrictions that could prevent efficient use of the storage space. It is also important that the warehouse management system (WMS) is fully compatible with the MFC or WCS systems that manage the flow of goods. Finally, it is worth assessing whether the company is ready to adapt its processes to automation, as such changes can affect the profitability of the overall investment.
What errors affect the performance of the system?
Mistakes when preparing the implementation of a warehouse automation system are often due to a lack of experience in planning the different phases of the investment. It is important to carry out the process carefully and gradually, with due consideration for each step, including the expansion of the structure.Before this system becomes operational, it is important to prepare the infrastructure, including adapting the WMS to work with warehouse automation.
A common mistake is also inadequate preparation of the buffer system and lack of quality control of the pallets, which can cause disruptions in operation and reduce efficiency. Care must be taken to ensure the quality of the system components, as poor pallet grade can limit the efficiency of the stacker crane. The adaptation of the machine to the logistical processes resulting from the audit is also an important aspect.
When implementing it, it is also worth considering the specifics of the facility in which it is to be installed. In existing halls, there may be a problem with the load-bearing capacity of the floor, which could hinder the implementation of the investment. In this case, it is worth considering an automated warehouse, which can be developed in stages, regardless of the state of the existing infrastructure.
FAQ
What determines the profitability of an investment in a stacker crane?
The profitability of the investment depends on the right parameters for the flow of goods and the planning of the storage space. The correlation of warehouse length, width and height is crucial. A well-adapted system contributes to process optimisation and return on investment.
What is a WMS?
A WMS is warehouse management software that works with stacker cranes. It enables ordered operations to be carried out automatically, optimising the storage and retrieval process. It also monitors stock levels in real time.
What modes of operation do the stacker cranes have?
The warehouse stacker cranes can operate in manual, automatic and semi-automatic modes. The manual mode is mainly used for servicing, while the automatic mode allows full automation. The semi-automatic mode is used in specific cases where operator intervention is required.
