Between 2016 and 2021, the number of warehouse illnesses and injuries almost quadrupled, from 42,500 to 80,500. Forklift accidents resulted in thousands of missed work hours and 73 fatalities in 2021–2022.
The actual data nonetheless depicts a dangerous workplace for warehouse workers, even if the growth in warehouses over these five years may have inflated the figures.
The Development of Intelligent Warehouses
Before software, containers were stored and retrieved in conventional warehouses by employees using dollies or operating forklifts. In “Raiders of the Lost Ark,” the Ark of the Covenant cargo is pushed by a worker to its ultimate resting place, where it is lost amid innumerable crates and permanently lost to history.
It’s more probable that future “smart” warehouses will look like “Star Wars.” Drones driven by artificial intelligence fly back and forth while robots like R2D2 work alongside humans to do the hard labor.
Modern warehouses use cutting-edge AI-powered technologies like computer vision and machine learning to increase safety, yet they are unable to provide complete security. However, the riskier parts of warehouse job, like moving bulky boxes and hazardous containers, will be replaced by robots. By monitoring the whereabouts of every item at all times and using data-driven analytics to identify overstocking or restocking issues, this technology will help improve operational efficiency.
The warehouse sector, which is experiencing a persistent labor crisis due to the continuous explosive expansion of e-commerce, is in dire need of all of this new technology. According to certain projections, the number of warehouse facilities would rise by 20% globally by 2025. The “Amazon Effect,” which has trained customers to anticipate deliveries the next day or even the same day, has also increased demand for quicker turnaround times.
While technology may not be able to address every issue, it should have an influence on warehouse operations, as shown by the introduction of modern pallets in 1917 and the lift truck, which later evolved into the forklift.
Automation and Robots: The Future of Warehouse Workers
There is more to the “smart” warehouse than meets the eye. You may be surprised to learn how near this future warehouse concept is to reality.
Amazon “handles millions of items” using an AI-powered robotic system named “Sparrow,” while Walmart plans to “roll out 19 autonomous forklifts across four high-tech DCs.” Alibaba, another massive retailer, “examines and optimizes inventory, forecasts demand, and generates replenishment plans” with the use of an AI-driven supply chain system.
Businesses are using the following automated systems:
Conveyor systems, automated storage and retrieval systems, and autonomous mobile robots are examples of automated systems that simplify the transportation and storage of commodities.
While aerial drones help with surveillance and inventory management, collaborative robots, or Cobots, operate alongside human workers.
Robots automate a variety of operations in the fulfillment process, including picking, palletizing/depalletizing, sorting, labeling, and packaging. Security robots also improve safety and security.
Even while only a tiny portion of warehouses now utilize autonomous forklifts, that proportion is predicted to rise dramatically over the next ten years. According to MarketsandMarkets.com, the market for autonomous forklifts is expected to grow from $4.6 billion in 2023 to $8.8 billion in 2028, almost doubling in size.
AI may cause some people to lose their employment, just as it does in other sectors. Companies should invest in keeping their employees to take on new roles and responsibilities and train human team members to work alongside robots, though, as a “smart” warehouse may create new jobs for the workers.
According to MTC Recruitment, businesses should support their staff members’ adoption of a mindset of constant learning and provide them upskilling in:
- Knowledge of data
- Analytics of data
- Basics of AI and robotics
- Upkeep and repair of robotics
- Cybersecurity
AI programming and machine learning
How human workers will interact with AI robots is another question. On Star Trek: The Next Generation, would it be similar to speaking with Data, a fully functional android? It doesn’t seem that way at the moment.
According to a new study comparing Germany and the United States, “people who work with the robots suffer negative mental health effects – and are more likely to misuse drugs or alcohol,” according to ScienceNews.dk. The article notes that because robots have eliminated more jobs in the United States than in Germany, drug use has increased more in the American workforce.
AI: The “Smart” Warehouse’s Secret
The warehouse’s brains will be powered by AI software, which will maximize inventory control, increase operational efficiency, and improve order fulfillment accuracy. Every stage of the warehouse operation will be tracked in real time by machine learning, computer vision, and Internet of Things sensors. Machine Learning or Deep Learning will keep improving warehouse operations because of its capacity to learn from data and experiences.
By evaluating past sales data, seasonal patterns, and outside variables to predict supply and demand, artificial intelligence (AI) algorithms allow inventory optimization, preventing stockouts and preserving commodities that consumers want. Analytics that anticipate maintenance issues before they arise will be provided to warehouse managers using data gathered from sensors on AI-automated machinery, reducing downtime and expensive repairs.
AI will be used by businesses to optimize delivery routes, reducing fuel expenses and truck wear and tear. Customer satisfaction rises when packages are delivered more quickly. These robots commonly connect with Warehouse Management Systems and Fleet Management Software for smooth coordination and optimization.
A further advantage is that “smart” warehouses should favorably affect the environment by minimizing waste, improving energy consumption, and simplifying transportation routes.
Challenges to Implementing a “Smart” Warehouse
These technologies have many potential advantages, but putting them into practice can be difficult due to factors like high upfront costs, complicated integration, heightened cybersecurity requirements, a lack of awareness of the importance of high-quality data, a lack of skills among employees, scalability, regulatory compliance, maintenance and upkeep requirements, and employee resistance to change.
But these difficulties are not insurmountable. Businesses must plan their automation transition if they want to succeed. For the transformation to be successful, they need cross-functional teams to provide a variety of viewpoints. To make sure the new process is functioning well, they could also choose to introduce intelligent automation gradually. Before moving further, a pilot program would demonstrate to managers, employees, and executives the advantages of the new automated system.
Integrating old systems with the new AI-powered technologies will be a huge problem. To properly combine both systems, organizations would require highly competent software engineers that understand the technology and the warehouse sector.
What does the future hold for smart warehouses?
Looking forward, the potential for smart warehouses is immense. An article, Supply Chain 24/7, proposes that warehouses will migrate to urban areas but, more crucially, will employ 3D printing technology “to ‘print’ products on demand and then package and deliver them just as they do products from inventory.”
Technology “will play a significant role in delivering the speed and efficiency required and automating the movement of products from large regional warehouses to the urban distribution centers while enabling faster picking, loading, and delivery of these products,” according to the report.
The “smart” warehouse of the future will include cutting-edge technologies like blockchain, which provides supply chain transparency, drones, which monitor inventory, and augmented reality, which helps employees. The “smart” warehouse of the future is being constructed now and will undoubtedly change as AI technology develops.