How We Designed and Built Intelligent Warehouse Systems

Picking Process Automation

The systems we design start by combining multiple seed orders into one batch, then follow system-optimized routing rules to improve picking or routing efficiency.
These automation systems are configured from a centralized software platform orchestrating both high-level and low-level flows while ensuring that the itemized master data in the system is accurate.

Graphical Monitoring & Dashboard Systems

Graphical monitoring system utilizes visual methods to display information clearly and quickly such as color-coded charts and various boards for visualizing work.
Dashboard System (1) establishes a comprehensive and reliable indicators; (2) uses visual effects to convey the information; (3) monitors information, finds answers, and views all metrics immediately; (4) follows data change consistently

Control & Monitoring

Equipment Control System:
1) support multiple operating devices; 2) regulate barcode management; 3) integrate automated logistics equipment

Material Control System:
1) resource integration; 2) unified execution rules; 3) apply big data algorithms to optimize efficiency

Monitoring System monitors various equipment and systems in real-time.

Heterogeneous System Integration

We use Heterogeneous Integration method to synchronize various operating systems into one single system via combining different semiconductor components with relevant technologies from different domains into a unified system.
Systems such as Enterprise Resource Planning, Supply Chain Management, Warehouse Control System, Manufacturing Executive System, Bill Of Materials, inbound, outbound, inventory tracking...

Shelving Options for Automated Warehouse

Simplified shelving, carousel with single exit, stacked trays, stacked bins & roller-conveyors, high speed conveyors, tall bin shelving, elevator & roller conveyor, large sized metal shelves, expandable wireless shelving, RTP charging station within high-up shelving structures, wireless shelving structure & foothold lanes, and automated palletizing shelving structure.

Equipment Options for Large Capacity Warehouse

1. Wireless RTPs carries 3tons/load at room temperature & 1.5tons/load in a frozen environment
2.Underground rail carts, escalators, conveyors systematically organize large/heavy loads
3. High-capacity cranes transload items in three-axes vertically
4. Intelligent visual sensing magnifies efficiency of robotic arms, AGVs, autonomous forklifts

Equipment Options for Moderate Capacity Warehouse

1. High warehouse shelves built for wireless ASRS operation
2. Combining elevators and conveyors to transport items horizontally and vertically
3. AI-guided high-speed high-density sorting, picking, and storage system
4. Intelligent robotic arms built with advanced visual sensing ability

Equipment Options for Compact Capacity Warehouse

1. A two-car garage sized warehouse operated by a built-in forklift
2. An automated storage area alongside a semiconductor wafers production site
3. A climate-control carousel storage with single access
4. Battery-operated TTT and AGVs

Assign Storage Areas

1. Fixed - Each type of material has one storage location
2. Categorical – Based on item size, weight, etc.
3. Randomization - System assigns according to statistical availability
4. ABC Rules - Programmed by preferred criteria such as traffic, order volume, etc.

Or a combination of above.

Warehouse Layout Design - Preliminary Tasks

1.Obtain knowledge of local building codes
2.Collect and analyze product inventory flow data
3.Conduct surveys for input from warehouses/distribution centers
4.Identify and define clear objectives during the planning stage

Design Principles 4 ~ 7

1. Flooring
2. Forward Staging
3. Balance Between Storage & Picking/Retrieving
4. Flexible & Scalable

Design Principle 1 ~ 3

A good warehouse layout maximizes the accessibility and security of all items.

1. Four Major Functional Zones
2. The Pareto Principle, or 80/20 rule
3. Warehouse ROI Based on Per Cubic Foot.

Efficient Warehousing Part B

Power of Running Successful Warehouse/Inventory Systems

# Reduce human errors 90%
# Reduce cost of goods 40%
# Increase space utilization 40%

Efficient Warehousing Part A

Power of Running Successful Warehouse/Inventory Systems

# Increase productivity 30%
# Reduce cost of labor 29%
# Reduce product returns 25%

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