Challenges in Modern Warehouse Operations
As e-commerce and omnichannel retailing continue to expand, warehouse operations face increasing pressure to fulfil orders faster, more accurately, and at lower costs. Traditional Goods-to-Person (G2P) systems, while highly efficient compared to manual processes, come with inherent limitations:
- Limited Batch Sizes: Traditional G2P systems restrict batch sizes due to pick port real estate limitations, reducing overall throughput.
- High Investment Costs: Expensive storage infrastructure and pick ports drive up initial investment.
- Double or Triple Handling: Often, products need to be inducted into the G2P system only to be picked again, leading to inefficiencies.
- Peak Demand Challenges: To meet peak demand, G2P requires a significant investment in robots and pick ports, making scalability expensive.
- Reduced Picks per Presentation: The necessity for multiple presentations of the same tote increases handling time and decreases efficiency.
The Solution: Combining tSort and AutoStore
Tompkins Robotics and AutoStore have partnered to create an optimized warehouse solution that combines the best of both systems. This integration enhances efficiency, scalability, and cost-effectiveness by leveraging the strengths of each technology.
Efficiency Improvements with tSort in G2P Systems
By integrating tSort with AutoStore, warehouse operations gain:
- Higher Batch Factors: Every G2P port can reach every destination, increasing the number of picks per presentation and reducing overall presentations.
- Lower Pick Port Requirements: With improved batch processing, fewer ports are needed, leading to lower infrastructure costs.
- Reduced Swap Ports: Since totes spend more time at the pick ports, there is less need for rapid swapping.
- Fewer Robots Needed: Because totes no longer need to be dropped at multiple locations, the total number of G2P robots required is reduced.
Storage Optimization with AutoStore and tSort
The combined system also enhances storage efficiency:
- Direct Induction for Full Cases: When a full case is needed for an order wave, it can be inducted directly onto the tSort, bypassing the G2P system.
- Lower-Cost Storage Utilization: Full cases can be stored in less expensive locations, reducing the overall size and cost of the G2P system while improving return on investment (ROI).
- Flexible Fulfilment for Various SKUs: While G2P systems tend to be sole-source execution solutions, the integration allows for a hybrid approach, making it easier to handle SKUs that fall outside the system’s “sweet spot.”
tSort and AutoStore: A Complementary Robotics Solution
When combined, these technologies create a seamless, highly automated fulfilment ecosystem that enhances productivity while reducing labour requirements. Key benefits include:
- Increased Process Automation: Reducing reliance on manual labour while ensuring 24/7 operation.
- Greater Order Processing Capacity: A single pick port equipped with tSort3D can manage up to 48 orders, dramatically increasing throughput.
- Enhanced Scalability: The modular nature of both systems allows easy expansion as business needs grow.
- Optimized Warehouse Footprint: The tSort system can be placed under an AutoStore, maximizing space efficiency without requiring additional real estate.
Integration Options for New and Existing Warehouses
This integrated solution is flexible enough to be implemented in both new and existing warehouse setups:
- For New Warehouses: The system can be designed from the ground up, optimizing space, efficiency, and automation from the start.
- For Existing Warehouses: tSort and AutoStore can be retrofitted into current facilities with minimal disruption, providing an immediate boost in efficiency without requiring a complete overhaul.
Conclusion: The Future of Warehouse Fulfilment
By integrating tSort with AutoStore, Tompkins Robotics is revolutionizing warehouse completion operations. This partnership delivers a powerful combination of automation, efficiency, and scalability, making it the ideal solution for businesses looking to optimize their logistics.
To learn more about how this solution can transform your operations, download our full white paper today.