The warehouse

automation blueprint.
It is estimated that by 2025, 50,000
warehouses across the globe will utilise
automation, capturing the gains provided
by that new dimension of productivity.
Be it the automation of commonplace load
handling or enhancing the wider operations
setting for businesses, automation is here
to add value across the board.

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This adoption is being driven by the flexibility and efficiency
gains that automation offers. With increasing market volatility,
driver shortages, customer expectations and trends such as
next-day or same-day delivery, the need for agility on the
warehouse floor is paramount. With advances in technology
and the possibility of reducing operational costs, automation
is the next step for guaranteeing efficient logistics flow.

Automation is a way of avoiding waste,

ensuring there is a seamless flow of both
goods and data at all times. But how is
this actually captured?

The warehouse automation blueprint. 3

Integrated automation for the warehouse floor.
Enabling step-by-step automation to enhance efficiency and productivity on the warehouse
floor is provided through utilising the right machinery for the job. On the market today,
businesses can benefit from various automated vehicles, such as automated warehouse
trucks, automated tow trains, automated carts and semi-automated shuttles.

These vehicles can replace the conventional mechanised automation that, more often than
not, requires a significant upfront investment and allows for minor infrastructure changes
once installed. Once used, you can optimise space, capture asset flexibility and reconfigure
operations - all-important advantages ready for a business considering automation to gain.

Some businesses may feel they are in the correct position to automate their material
handling but are not yet fully convinced they need it. The flow of material through a site
owes itself to logical consideration and through answering the right questions, a business
may find itself in need of automation.

We have developed this checklist with those businesses in mind to get to the point where
common functions can be identified as configurable modules for repetitive use. This is what
warehouse automation is aimed at, separating the unique from the repetitive and optimising
across the board.

Use this resource to discover whether your business might benefit

from warehouse automation.

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 ?

The questions to ask

before considering
automation.

Logistics is experiencing a renaissance due to automation, capturing

efficiency gains and reducing the operational costs traditionally associated
with warehouse management. However, this does not mean automation is
the answer to everything. Every logistics flow, every warehouse setup, every
supply chain is different. What works for one, may not work for another.

The key is determining where unnecessary processes can be eliminated,

adding value to the points that need it, ensuring a workforce is
complemented by automation in all the places that matter.

Before considering implementing automation, ask yourself the

following questions.

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 Are warehouse-driven
delays a common issue?
Without the right processes or machinery, problems with inventory tracking, picking,
receiving and putaway can regularly halt the flow of materials through a warehouse.
For example, raw materials may not be received properly, causing delays as employees
search for the right products.

Automated vehicles can be programmed to ensure material flow is not affected by

human error, ensuring the transported goods reach their destination and do not upset
other logistic processes.

Do everyday workflows include a vast

amount of manual, repetitive tasks?
Manual, repetitive tasks take time and effort to complete. For a workforce,
they can seem endless and result in not focusing on bigger picture tasks that might
be more important.

Through onboarding automated guided vehicles (AGVs) within a warehouse setting,

warehouse managers and logistics teams can rest assured the step-by-step flow of
materials can continue uninterrupted and focus on other vital tasks that require
their expertise.

Is output directly affected by

limitations within the workforce?
Human errors can be commonplace. Sometimes they are small issues that are not
genuinely felt by the wider business. Other times, they are big, causing obvious delays
or decreasing productivity levels. Whatever the cause may be, human error within
warehouse logistics can and will happen.

While there is no foolproof way of guaranteeing no problems will occur, logistics teams
can limit risk by introducing automation. The mix of software and hardware is an easily
controlled, visible way of tracking inventory and making sure it keeps moving.

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 Are inventory counts regularly
affected by inaccuracies?
With the volatile global business environment and the high expectations of customers
and clients, it is no longer viable to carry out manual inventory tracking. Improvements
in warehouse management, such as integrated inventory management, mean visibility
over inventory is easily accessed, reducing the amount of counting inaccuracies that
can lead to misplaced stock.

Do you use a Warehouse

Management System (WMS)?
Sitting at the manufacturing and supply chain centre is a WMS, working to track
inventory, manage labour and implement transportation management.

With the right automation systems, businesses can experience a truly integrated,
real-time warehouse management system to ensure lean logistics and continuous flow
are uninterrupted. The right WMS guarantees maximum value added to operations and
the optimisation of current processes.

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 Do you find there is either insufficient
or surplus labour on-site?
Too little or too much on-site labour is a problem. With too little, businesses find
themselves stretched and unable to fulfil projects on time. With too much, inaccuracies
may be more common and unmanaged employees will likely cause more delays.

In general, businesses are finding the boom in e-commerce is compounding labour

challenges that are being felt, with shipment volumes growing and customers
demanding much faster delivery times.

The potential of automation lies in supporting on-site staff, taking those time-intense
and repetitive tasks away and completing them with both precision and speed. Overall,
automation helps meet common warehouse challenges, stimulating continuous
improvement and better consensus building, decision-making and teamwork.

Questions like these are expected within the warehouse setting.

If you have found yourself answering ‘yes’ to most of these
questions, then it is more than likely that some form of automation
could benefit your warehouse management.

The question now is, how do you determine

which is the right automation provider to
work with?

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 ?

The questions to
ask when selecting
a provider.

If the previous section has you considering the efficacy of automation, you
will also need to determine what kind of automation solutions provider your
business would most likely benefit from working with.

The following questions will help you decide what kind of

organisation that is.

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 Does the provider have a proven
track record of supplying quality
automation solutions?
Identify whether a provider has a long history of providing superior quality machinery
within various industries. Ask yourself:

L Are their products well-reviewed?

L Do they have much experience?

L Do they operate globally or locally?

L Do they satisfy several warehouse-related needs?

Can the provider offer evidence or case

studies of successful automation projects?
The right automation provider will display their history of success, delivering AGVs
and enhancements to warehouse and logistic management systems.

For example, if you would like to discover how Toyota Material Handling UK has
provided automation solutions for a wide variety of companies across the UK and
beyond, visit our website.

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 Does the provider offer ongoing
support and maintenance?
An automation provider should supply quality products and quality service packages,
complete with service plans that maintain trucks and AGVs, helping get the most
out of those assets and keep logistics operations moving.

Regular maintenance prevents downtime and substantial repair costs with skilled
technicians that can accurately fix any technical issues that may occur. These services
should be scalable, with the ability to be tailored to a specific business — no matter
the industry or size.

Is there the potential for a

complete end-to-end service?
Depending on the needs of your business, the vendor should be able to provide
a full service, from concept up to delivery and maintenance. This should include:

L The maximum level of performance

L A comprehensive parts and labour plan

L Breakdown cover

L Preventative maintenance

L Thorough examinations to ensure truck compliance

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 Can the provider deliver in a
timeframe that suits your needs?
The right provider will offer a transparent timeframe for servicing and delivery, with
no hidden costs. Look for the vendor who can guarantee a quick turnaround on project
delivery, with local specialists on hand to make sure automation can be implemented
quickly and accurately.

Additionally, servicing and maintenance should also be delivered quickly. Here at Toyota
Material Handling UK, we guarantee a four-hour response time and the delivery of any
needed parts within 24 hours.

Answering these questions enables businesses like yours to better

determine what kind of automation solutions provider they would
potentially work with.

To conclude, you should always look for

a provider who can guarantee respect
and trust.

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Solutions from Toyota.
Here at Toyota Material Handling, we have over 100 years of
combined experience in delivering the highest quality material
handling solutions on the market today, each developed with
innovation in mind.

Our automated material handling solutions work to automate various sections and
processes within a warehouse, such as:

Block stacking

Light item handling

High-level storage

High-density storage

Our dedicated material handling experts can help automate to eliminate ‘muda’ — the
Japanese word for waste - creating a streamlined process that can be applied for multiple
real-world applications.

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Put-away.
The transportation of pallets from inbound areas to put-away areas can easily be
automated using stacker trucks, low-lifter trucks, counterbalanced trucks or reach trucks.

Replenishment.
Maintaining a consistent flow of material means guaranteeing efficient replenishment.
Our vehicles, such as automated towing trucks or stacker trucks, guarantee the refilling
of parts and smooth and safe pallet transfer.

Point-to-point transport.
Distribution centres house multiple pallets transported from inbound to outbound in
processes known as ‘cross-docking’. Our AGVs take care of the transportation of goods
between conveyors or floor buffers, for example.

Empty pallet handling.

Empty pallets are common in both warehouses and manufacturing sites. Automated
vehicles can take pallets from assembly or kitting stations to pallet dispensers or bring
them to production areas to load finished goods. This can be done automatically
or on-demand.

Finished goods to outbound.

When products are ready for delivery, automated vehicles will pick up the goods at the
final stations. If wrapping is required, those vehicles will take the items to the wrapping
station and then the outbound area.

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Why Toyota?
From consistent innovation to research and development,
from quality service to real accessibility, Toyota Material Handling
is one of the leading providers of trucks and automation. We are
here to enable you to make the most out of your equipment,
warehouses or manufacturing facilities and your entire
business overall.

Our trucks provide peace of mind for business owners, logistics teams and warehouse
managers. Each one is extensively tested and serviced by our experts throughout their
lifetime, guaranteeing quality from concept to delivery.

It is not simply about hitting targets, but it is about working in line with the five values we
uphold in our day-to-day operations, what we call ‘The Toyota Way’. We are here to help you
journey towards your business’ true north by offering respect, efficiency, zero waste and
quality in everything we do.

If this resource has piqued your interest or resonated with any of the considerations
you are experiencing and you would like to learn more, get in touch with Toyota Material
Handling UK today.

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Helping you do what
you do best — book
a consultation today.
Toyota Material Handling is the world’s number one in developing and
producing innovative, high-quality material handling solutions. We are
here to ensure you get the most out of your equipment and warehouse
configuration — from the shop floor to the site infrastructure.

If you have more questions about warehouse automation or

automated vehicles, talk to one of our experienced specialists.

For guaranteed quality, reliability and respect,

contact us today.

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