The Benefits When Considering Automation

The Benefits When Considering Automation

AutoStoreIn today’s ever-changing market, automation is the leading edge most companies are using to gain a competitive advantage. Companies delaying automation will fall behind, primarily due to the brisk speed at which innovation is already being adopted in the market. The pandemic showed the world that the current supply chain model was modeled after a world that does not exist anymore. Customers demand easy access to products, speed of delivery, and high-touch customer service. However, many executives are unsure of where to begin with automation, what products are right for them, or even what company they should be using, causing them to delay the process altogether. By automating your business, you can execute operational activities more efficiently. Robotics take care of monotonous tasks while employees can focus on main business processes and more complex tasks. The below highlights some key benefits to automation:

Autonomous Mobile Robots Reduce Human Movement & Injury

OTTO AMRPULSE Integration partnered with OTTO Motors to complete the largest at scale deployments of AMR technology in North America. During the study, PULSE compared AMR performance to existing technologies and human load factors. The result, AMRs represented 10% of the equivalent manual handling labor costs and 20% of the cost of a forklift.  It is important to note the situational aspects associated with this study. At higher speeds and with advanced safety features, AMRs outperformed manual carrying, and driver operated pallet loaders over long distances. However, humans have more agility moving goods for short distances or around stations.  It was determined that a blend of both would create the optimum result with output and efficiency. AMRs would conduct the heavy lifting and repetitive labor while humans would operate at stations carrying out tasks of picking, sorting, or quality control. Reducing the number of people moving around a facility compounded with the risks of human driver error, and injury related to repetitive “heavy lifting” tasks helped alleviate some of the many key hazards companies continue to face leading to costly accidents in their facilities. Due to materials handling automation, the repetitive task of pushing product is assumed by the vehicle, while more value-added tasks are left for the workers. Injuries decrease and overall company injury related costs decrease as well.

Integration Into Existing Equipment

WMSWhile researching supply chain automation, it is important to consider solutions that complement the equipment you already have or plan to buy. Some autonomous vehicles, including those from OTTO Motors, integrate with a warehouse management system (WMS) to reduce unnecessary steps. Compatibility between equipment makes the installation of new products more efficient.

Scalability

Scaling a business can be a complicated process. There are many variables that add to a business’s operational costs when it’s being scaled. The more manual process your business has, the harder it is to scale that business. When you automate your processes though, scalability becomes easier. All a company needs to do is make sure that systems can accommodate that growth. If not, minor upgrades are all that is needed.  System’s like AutoStore are easily scalable solutions for retail and e-commerce applications.

Increased Collaboration

An added benefit to automation solutions is that it allows increased collaboration among teams. Many believe automation results in job loss and less teamwork. However, it’s the exact opposite. When repeated tasks are automated, staff will have more time to focus on more integral aspects of the business. Instead of doing mindless repetitive tasks, they’ll work together to make the business better. When business processes are done manually, teams will have to dedicate all of their efforts just to keep things moving. This results in wasted human potential and allocating the valuable brainpower and creativity where it is not utilized effectively.

Accountability

AccountabilityWhen a business is automated and streamlined properly, it’s easier to assess responsibility. This comes as a result of having clear, well-defined tasks, with all the minor tasks automated. If your business has many small tasks that are not automated, they tend to become “nobody’s responsibility”, as none of the staff is directly responsible for them. When these tasks are automated, you end up with the few important tasks where staff members are directly responsible. Having this clear responsibility distribution increases the staff’s accountability for work done and makes quality control easier.

Trackability

Automated and digitalized processes are much easier to track. Your system knows exactly the time, effort and resources required to carry out a specific task. Using the right tools, you can get valuable business insights that’ll help you make it better.

PULSE Team Makes The Difference; Chris Shepperly

PULSE Team Makes The Difference; Chris Shepperly

Every industry and company possesses crucial skills, core competencies, and features setting it apart from the competition in an ever changing world.
 
At PULSE Integration, we are industry leaders because every employee embodies our culture. Our values provide us with the compass that directs our teamwork, sensitivity to client’s needs, and fuels our commitment to excellence. Our value is in the strength of our ever growing talent.
 

Chris Shepperly

We take this time to recognize one of our valued associates, Chris Shepperly. Chris is a solutions engineer with over 10 years of experience in automated material handling systems. He is highly proficient in full system design and complex technology applications. While Chris remains a relatively new employee, he has immediately integrated into the Solutions team and has become a key and a pivotal client facing team member. It is here he uses his analysis of data to support best system requirements for design specification.

 
Chris has proven himself as a competent communicator with a focus on client satisfaction. Equipped with sensitivity to understanding client expectations he is able to design best in class material handling implementations and data driven solutions in the supply chain. His years of experience in the practice of 3D concept generation, modeling, and designing systems for fortune 500 companies has allowed him to be both proficient and creative in designing highly complex systems from inception to completion. Combined with his attention to detail and unmatched dedication toward client satisfaction, allows Chris to generate solutions that are incomparably the finest in the industry. This allows PULSE to create a more user-friendly customized solution for every client.

How does this translate to our clients?

What’s in it for you by working with Chris and PULSE? Why should you choose PULSE for your system integration experience?

Center of Excellence Michigan

Our Team Is Unsurpassed
While showcasing a case study is a boastful example of completed work and capabilities, it does not speak as loud as continuously executing at a high level. Our team continues to develop best in class processes and reacts seamlessly to unforeseen obstacles. Team members like Chris are able to quickly determine our clients challenges and needs. This, combined with the understanding of system design, gives Chris and others the ability to create a multitude of options and unique approaches to client solutions. It shows our team has the ability to think through and effectively communicate the strategy and options available. We align our attributes and ability with a personalized approach to client goals.

 

We Are Genuine In Our Follow-Up
One of the most neglected aspects of business is feedback. We are committed to LifeTime Services after the completion of a project. We actively listen to all suggestions as a methodology to continually improve our practices and we have a genuine interest in our client’s success.
Our Clients Are Our Priority
We’re an extension of each client’s team, and they’re a part of ours, so it’s important to set these expectations up front. Great work, exceptional service, new ideas, and long term relationships make us the perfect fit for any client team.

Leading Material Handling System Solution Provider

You Are Not Just Another Client
When someone asks why PULSE over other system integrators our response is the truth, we produce results and we get the work done. We take pride in the work we do and we care how each aspect of our business is shaped. To us, clients are not just another client, and we ensure each and every interaction with our team is personalized and unique to their needs. System engineer’s like Chris actively listen to our clients to ensure we are meeting their short and long term goals. The foundation of our culture is carried by each employee as a compass to direct our business.

50 Years of Innovation

We Are Experts In The Industry
With over 50 years of experience and working with dozens of change-making organizations, we understand how to leverage the right talent and technology mix to amplify a clients mission-driven work, while addressing the challenges and opportunities that come along with being an enterprise.
We Are Adaptable
Prior to the pandemic most companies were faced with their workforce now working from their remote offices. However, at PULSE we never missed a step. Our team seamlessly transitioned as most of our employees were already remote based. Being a great partner requires a team with a mindset of continual transformation. Innovation and how consumers make purchase decisions evolve by the minute. We understand what worked a year ago may not be what drives market share. We invest creativity and innovation in designs with team members like Chris so we are ahead of what’s next and we have the ability to scale to give our clients an advantage in their market.
 
At PULSE we feel personally responsible for advocating for our clients and business partners to provide solutions that exceed expectations and operate with integrity, transparency, & honesty.
Top Material Handling System Solution Provider

Top Material Handling System Solution Provider

Leading Material Handling System Solution Provider

PULSE Integration has been featured as a top material handling system solution provider for 2021 by Logistics Tech Outlook Magazine.

Logistic Tech Outlook provides an annual listing of 10 companies that are at the forefront of providing material handling system solutions and transforming businesses.  The magazine is read by over 68,000 subscribers who are key decision-makers in the logistics sector.

The magazine also features contributory articles from senior management executives from distribution, warehousing, manufacturing, supply chain experts, logistics professionals, and other technology decision makers on how material handling solutions improved operational performance in their organizations.

Read The Article Here

PULSE Welcomes You To ProMat DX

PULSE Welcomes You To ProMat DX

ProMatDX
ProMatDX, held April 12-16, 2021, is the new digital event experience designed to power up manufacturing and supply chain professionals from the U.S. and over 140 countries with critical access to the latest solutions they need now to improve the resiliency and agility of their operations.
ProMatDX combines the power of the connections, solution-sourcing and education that only ProMat can deliver with the latest digital event technology in a five-day event that will be the most important week of 2021 for the manufacturing and supply chain industry.
Attending ProMatDX is your unrivaled opportunity in 2021 to find solutions, connect with your peers and leading solution-providers and learn the latest trends and technologies that will take your supply chain to the next level of success. PULSE will be featuring state of the art order fulfillment technology at the upcoming virtual show. Make it a point to visit us

Click Here To Visit Our Showcase

Brittain Ladd, Andrew Benzinger of AutoStoreDon’t Miss Out On These PROMAT DX Educational Sessions!

Micro-fulfillment is one of the most talked about but least understood solutions on the market. Attend this session to learn the Who, What, When, Where and Why of Micro-Fulfillment.
PULSE’s own Chief Marketing Officer, Brittain Ladd, will be co-presenting with AutoStore’s Andrew Benzinger on the topic Why Micro-Fulfillment Is a Must Have.
Learn how combining additional technologies will supercharge your fulfillment strategy and create a competitive advantage
Mark your calendar for this revolutionary educational seminar held April 12, 2021 from 1:30 PM – 2:00 PM CT
Matt Chang and Matt RendallPULSE Integration’s Chief of Strategy & Innovation, Matthew Chang, and OTTO Motors CEO and Co-Founder, Matthew Rendall, share information about The Business case for AMRs in Manufacturing vs. forklifts, conveyors, and other modes of material handling at both greenfield and brownfield facilities.

This session is focused on providing a detailed discussion on the value of AMRs within a corporate supply chain.

Speaker Matt Chang, one of the most experienced experts on the topics of AMRs, will introduce content specific to the importance of companies adopting AMRs and the business case for doing so. Real world examples of how AMRs have been introduced will be provided. Check out more about PULSE’s AMR deployments here. Read our Business Case for AMR’s in Manufacturing here.
Mark your calendar for this revolutionary educational seminar held April 14, 2021 from 9:30 AM – 10:00 AM CT

Don’t Forget to View PULSE’s Product Demos at the Show….

PULSE.exe
PULSE.exe
Software Solutions
April 14, 2021
10:00 AM CT
AMR Solutions
PULSE
AMR Solutions
April 13, 2021
10:00 AM CT
PULSE Solutions
PULSE
Solutions
April 12, 2021
10:00 AM CT
AMRs in Manufacturing

AMRs in Manufacturing

OTTO Motors and PULSE Integration have partnered to implement one of the world’s largest deployments of AMR technology. The OTTO material handling platform was deployed at a billion dollar company that is a household name in consumer goods. This was in part because of the ability for the AMR platform to flexibly, reliably and safely move materials but the strength of the business case was a deciding factor in the choice to implement OTTO.

The following conclusions were drawn after a detailed analysis of the OTTO platform vs alternative material handling methods for the customers. When compared for productivity and costs:

  • OTTO was 10% the cost of a full-time equivalent for manual cart movement
  • OTTO was 50% of the costs associated with a driver and a forklift.
  • OTTO was 66% the cost of an AGV equivalent
  • OTTO was 50% the cost of a conveyor equivalent

When the customer began its work with PULSE to transform its operations, four methods of material transport were considered. The customer needed a flexible, reliable and safe solution that would optimize materials movement. OTTO AMRs were found to be more flexible than a conveyor and safer than a forklift. The deployment resulted in an ROI of less than two years, and significant cost savings for the operation. The payback drivers included labor savings, increased productivity, improved safety and ergonomics for operators, lower capital costs, and a more compact facility design.

Competitive Advantage Through Automation

Automation has long been used to improve efficiencies within manufacturing as a way to gain competitive advantage. To see how automation has made an impact we need only look at the automotive industry where automation made Ford’s mass production possible and profoundly changed the world.

Today, lights out production–where entire factories are automated–promises the highest efficiencies, but remains elusive for many manufacturers. One of the last forms of automation to make its way onto factory floors is materials handling. Moving materials has remained predominantly a human task. And because it has been considered one of the lowest valued tasks on the factory floor, materials handling has been ripe for automation.

Advancements in robotics, computing power, and AI have made way for a new class of automation for material handling to emerge. The autonomous mobile robot or AMR combines the flexibility of a human with the efficiency of a conveyor while safely moving materials in pedestrian-heavy areas. The first industrialized implementations of the technology have in the last decade. Yet, there have been few examples of meaningfully scaled deployments in manufacturing.

One Company.
Two Scaled AMR Deployments.

OTTO Motors, one of the pioneers of the AMR industry, partnered with PULSE Integration to implement one of the world’s largest deployments of AMR technology. The companies deployed the OTTO Materials Handling Platform at a billion-dollar company that is a household name in consumer goods.

PULSE Integration was initially retained to evaluate various materials handling technologies for two facilities, one greenfield and one brownfield. AMRs, conveyors, forklifts, and automated guided vehicles (AGVs) were evaluated for comparative productivity and costs. The OTTO Materials Handling Platform was selected for both sites. The decision was made because of the ability for the AMR platform to flexibly, reliably, and safely move materials. The strength of the business case was also a deciding factor in the choice to implement OTTO.

OTTO Autonomous Mobile Robots:

10% THE COST

of a full-time human labor equivalent

20% THE COST

of a driver and forklift

Cost savings resulted in:

ROI of <2 YEARS

and

IRR of >50%

OTTO Autonomous Mobile Robots were found to be 10% the cost of a full-time equivalent for manual cart movement and 20% of the costs associated with a driver and a forklift. OTTO was also compared against fully automated technologies. Again, when directly compared for productivity and costs, OTTO was a fraction of the cost of traditional conveyance and automated guided vehicles (AGV). These cost savings resulted in an ROI of fewer than two years and an IRR of >50%. To achieve these results, the payback drivers included labor savings, increased productivity, improved safety and ergonomics for operators, lower capital costs, and a more compact facility design.

Deployment Considerations

A number of deployment considerations were taken into account for the deployment of the OTTO Materials Handling Platform.

OTTO Materials Movement Platform

Design

A critical part of the project was in the design phase. The goal of this phase was to design the optimal flow of materials. Simulation was used to compare machine and material staging layout configurations to aid the customer in making decisions about facility layout. By simulating the process options ahead of time, the customer was able to make the best decision for layout and process while de-risking the deployment well before the commissioning of the fleet started.

The teams also used simulation to test how AMRs would react in every scenario. For example, they were able to model the physical constraints of the operation when testing against various parameters like vehicle speed, traffic management, and opportunity charging. Simulation allowed the system designer to stress test the AMR fleet and check for “corner cases.”

A thorough design phase can also be used to prepare for the following situations:

  • Restarting a facility after a prolonged shut down (holiday shut down)
  • Manufacturing line change over from one product to another
  • Recall of goods in an eCommerce operation requiring reverse logistics
  • “Cut-over” of plant from manual to autonomous operations
  • Introduction of new work process

Safety

The downside to manual material handling goes beyond poor utilization of a limited human workforce, it also presents health and safety risks. According to the US Department of Labor, materials handling is the number one cause of compensable injuries. The various mechanisms for transport that are human-powered, such as traditional fork trucks, are fraught with safety issues that can result in injury or death.

OTTO was designed to work around people and other vehicles.

OTTO AMRs are pedestrian-safe robots and use safety-rated sensors. Simply put, OTTO was designed to work around people and other vehicles. This is made possible through sensor fusion and onboard AI to enable local route planning and collision avoidance. OTTO routinely navigates traffic with other vehicles at intersections and passing scenarios using OTTO Fleet Manager. “Rules of the road” can be custom configured per site, including speed limits and sensor sensitivity. Further, OTTO can be programmed to understand the overhang of a load and to account for oversized loads while maneuvering.

Payload

At the Greenfield facility, OTTO 100 was used to replace the human labor of transportation carts of materials and goods. The equivalency between humans and AMRs in terms of transport workload is at parity. AMRs travel faster over long distances and their maximum speed is 4.5 miles per hour (a light jog). In short transports and docking maneuvers humans are faster and more nimble.

OTTO Motors Payload

As a general conversion factor for a large workspace (>100,000 SF) a designer can use an AMR to Human equivalency factor of 1:1. For smaller spaces (<50,000 SF) a more detailed study of maneuvers may be needed to establish the true relationship. The findings from the design was that the OTTO platform generally outperformed simulation expectations.

At the Brownfield facility, OTTO 1500 was selected to replace forklift labor of transporting loaded pallets of finished goods and raw materials. OTTO 1500 can carry a payload of 3,300 lbs on a pallet. OTTO 1500 is compatible with all of the pallets in the facility which included:

  • Common wooden pallet types
  • Plastic pallets
  • Supersack on pallets
  • Vendor supplied raw material pallets
  • Manufactured WIP and finished goods pallets

The OTTO 1500 is capable of interfacing with manual or automated forklifts via the use of pallet stands, which enable load transfer and for the OTTO1500 to drive underneath the pallet load. While in transport the AMR is beneath the pallet load, meaning the space requirement for maneuvering is little more than the pallet dimensions. Automated processes can be implemented with retrofits to existing equipment or AMR interface design of new equipment.

The Network Effect of Scale

As more AMRs are deployed in the system, the more efficient the entire fleet becomes. As an example, consider that in an operation with substantial human labor, the humans cannot simultaneously communicate to each other. Instead, humans rely on hearing, line of sight, and communication devices like radio. One human that is idle is not instantaneously alerted to a condition of extra work being required somewhere else in the operation. With AMRs, the communication is immediate and the dispatch from Fleet Manager to an idle AMR is done using a combination of computer logic and artificial intelligence. Therefore, as the AMR fleet size grows the efficiency of the fleet improves. For large footprint operations at scale, AMR efficiency can exceed human efficiency.