While many companies often mention integration as an essential part of implementing a new automation solution, there isn't much information or discussion on how this can be achieved.

An automated warehouse system represents a significant investment, but it could cost even more when system integration is done wrong. Likewise, a disorganized or rushed implementation will result in inefficient or, worse, counterproductive hardware that could cost more to fix than completely reintegrate. On the other hand, when warehouse management system integration is done right, it might lead to an even better ROI than initially expected.

The role of system integrators and robotics technology suppliers

Systems integrators design, source, implement and maintain automated warehouse solutions for distribution centers. They link all components within the system efficiently – for fast and smooth process flows. The thing about robotics systems integrators is that they appear to be the middleman.

Why would anyone bring an intermediary if you already know what you want and have direct contact with the suppliers? System integrators do more than install equipment and integrate it with your current systems. They look at the whole process, from inbound to outbound, helping you build a system that not only deals with installing single pieces of equipment but prepares your business for growth. 

Automation system integrators can also identify the problems affecting your productivity or efficiency rates, helping improve those numbers and maximize ROI, considering long-term business goals.

A robotics technology supplier develops innovative technologies that address warehouse or distribution center challenges. Nowadays, we see companies developing kinds of warehouse robotics technology such as AMRs, AS/RS, ACRs, robotic arms, multi-shuttle, and the list goes on. While there's a significant demand for these solutions, a warehouse manager cannot simply acquire one type of robotic solution and hope it will solve all the problems. The trend is finding and developing ways to smoothly integrate with other technologies to provide integrated solutions to increase efficiency, maximize space, optimize processes, reduce costs, and more.

The Dynamic between BPS and HAI ROBOTICS

To deliver automation successfully, a combination of both stellar equipment, deep client business understanding, and systems knowledge must be present at the foundation. For Malcolm Druce, Joint-Managing Partner at BPS Global (Australia), the relationship with HAI ROBOTICS is based on a mutual willingness to learn, share and help each other, fueled by a shared passion for providing easy and fast automation for clients with a previously unattainable ROI.

Australia's largest online bookstore Booktopia partnered with BPS Global to deploy the latest autonomous robot technology to increase capacity and improve the fulfillment and putaway rates at its national distribution center (DC) in Lidcombe, NSW.

With an array of automation and technology solutions in its portfolio, BPS Global assessed Booktopia’s needs and recommended the HAI ROBOTICS solution. After completing a proof-of-concept consisting of 10 robots last year, BPS Global analyzed the data and established that the ACR system would provide Booktopia with the increased capacity required, alongside a significant increase in speed to market accuracy and fulfillment rates.

The putaway rates improved by an impressive 800%, and benefits rolled out further across the business. The solution integrates with a recirculating conveyor design. The same tote can travel to different robotic workstations and also recirculate in the workstations. It does not need to go back to the robot immediately after picking at the workstation. Furthermore, the ACR operates in a self-contained area, removing the element of an interface between forklifts and people, which is one of the most common causes of accidents in the materials handling industry.

Integration challenges

The main challenge in integrating components of an automated system is not necessarily the sequencing and timing of tasks through multiple different pieces of MHE (material handling equipment) but the integration between the equipment control system and the ERP/WMS.

Challenges exist when the ERP or WMS does not have the functionality to enable integration, which is the case with many customers. Complexity appears when some of the WMS functionality does not exist, and the expectation is for the equipment control system to fill the functionality gaps.

Understanding the functional capability of all IT systems involved in a solution and the 'demarcation' lines and responsibilities that are in place between the ERP/WMS and the equipment control systems helps to minimize the challenge. With the understanding of how the WMS is tasking the automation (pick waving, order release timings, order pick priorities, for example), companies open themselves to sub-optimization of the automation, which results in disappointment and (potentially) an inability to meet the customer promise rather than enhancing it.

A significant risk to integration can occur when a company does not integrate the automation solution with the operating processes in place within a distribution center. No matter how technically good an automation solution is, automation will deliver a sub-optimal outcome if time is not spent understanding, refining, and integrating business processes.

Why is integration important?

Automation systems are not standalone systems. They combine with other components of an overall solution, they integrate with operating processes (and often enable processes), and they need to take 'direction' from a host that provides instructions and takes task confirmation. In addition, the equipment and software of different suppliers have to work as part of a total unit. For equipment and software from different suppliers to work together, they need integration to be functional.

On top of integrating components, automation is introduced for several business reasons. One of the main reasons is to support the customer promise through increased speed to market. Automation 'integrates' business strategy and distribution center processes to maintain, enhance or improve an organization's ability to consistently meet its customer promise.

Why does it matter to the end customer?

A company's supply chain is the core that supports production, sales, distribution, and finance. Automation is an enabler that can either help the supply chain be more consistent and stronger or can cause the supply chain to stop. The end customer is the final judge of how efficiently the automation system works.

HAI ROBOTICS provides three levels of integration for those who need to start from scratch or simply plug straight into existing infrastructure. But having a reputable and experienced system integrator delivers extra benefits. BPS Global has played a crucial role in helping optimize Booktopia's supply chain and distribution operations. As a result, increasing its capacity and servicing its customers quickly, efficiently, and accurately.

"Being able to hold more stock was our first driving factor, but we also wanted to explore how we could drive efficiency around picking and putaway, and the HAI ROBOTICS solution from BPS Global ticked all of these boxes."

--Wayne Baskin, Chief Technology Officer at Booktopia