Easing Recall Burdens at the Warehouse

Compared to a conventional warehouse storage system, a high-density AS/RS allows warehouses to improve their space utilization so companies can store more products, more efficiently, in a smaller amount of space. For the food industry, the speed that an AS/RS moves products in and out of the warehouse prevents the spoilage of goods, like meat and dairy products. It also enables just-in-time order fulfillment strategies, a methodology in which orders are brought out when needed instead of staged hours in advance. This attributes to keeping products fresh and safe, as perishable items are stored in their respective freezers until the truck arrives. In these cases, when the truck “checks in,” the WES directs the S/RM to dynamically pick and deliver the appropriate product to its designated area for loading. At the same time, an AS/RS provides safer materials handling and reduces redundant, error-prone manual picking processes, thereby decreasing the likelihood of product damage and contamination.

Implementation Considerations

The beauty of an AS/RS is that it can be installed in an existing warehouse or designed specifically for a new facility. However, many companies considering the technology are unsure where to begin. Here are a few considerations to get started.

Carefully select your vendor. The vendor should possess credentials in your industry vertical (food, beverage, frozen goods, etc.), and therefore, will better understand your business’ unique requirements. As a result, the vendor will be able to recommend, develop, and implement a solution that meets your particular needs.

Purchase high-quality equipment. Lower cost does not mean a better business deal. You’ll find that your initial savings will soon be replaced by expensive equipment downtime and repairs.

Consider the long term. Success is not achieved overnight, so be patient in realizing results. Usually, you must implement progressive steps over time before obtaining return on investment (ROI).

Involve operating personnel from the get-go. Do not wait until the system is about to go live to involve key staff—operating personnel should be part of your project team from the start. This reduces the learning curve and helps with buy in.

Be proactive. Follow recommended preventative maintenance schedules instead of waiting for something to break at the most inopportune moment. You will not have to pay for expensive, major repairs down the road, and will avoid delays that negatively affect customer satisfaction.

Positioning for the Future

While warehouse automation technology—a WES and an AS/RS—can help food professionals keep products fresh, prevent and mitigate recalls, enable compliance with industry regulations, and protect consumers, they also provide long-term benefits that generate additional cost savings. The WES-AS/RS combination allows companies to improve overall efficiency, meet growing customer demand, raise productivity, lower risks, boost throughput, and increase inventory accuracy. Plus, an AS/RS has an average lifespan of 25 to 30 years, so ROI is often realized in the first five years.

For companies considering a WES, it is important to note that although a WES is able to replace WMS and WCS applications altogether, its flexibility allows for various deployment options. With a WES, users can enable or disable the WCS functions as needed. This approach lets companies implement an integrated WMS and WCS solution, while only using the functionality needed at the time. As the company’s needs grow and automation is introduced, the WCS functionality can be enabled quickly, saving time, training, and other costs associated with buying a new system.

As reports of recalls and industry regulations show no signs of slowing down, it is up to food professionals to investigate new means for mitigating these harmful incidents and promoting food safety. The answer lies in technology, and warehouse automation is a key piece of the puzzle.