In an ideal world, manufacturing and distribution operations would be based in state-of-the-art, energy efficient facilities. The reality, of course, is that top quality space is at a premium and few organisations can afford the cost and risk associated with relocating to new, modern locations and must squeeze as much value as possible from existing sites.

As Wouter Satijn, Chief Revenue Officer, Joloda Hydraroll, explains, automation within unloading and loading processes can transform the use of existing space, improving productivity up to fourfold and delivering essential operational agility.

Space Premium

Almost half (47%) of warehouse occupiers expect to expand within 12 months, yet with space, both production and warehouse, at a premium across the UK and Europe, achieving this goal is far from straightforward. Adding space is becoming ever more expensive, not least because new energy performance standards in the UK are expected to leave upwards of 50% of warehouses unlettable by 2030.

With companies understandably seeking more modern, energy-efficient facilities to meet ESG goals, reduce operational costs and embed new technological solutions, the cost of usable space is inevitably rising. But do organisations really need as much space as they think? Slick factory operations have maximised efficiency, using IoT and zero touch processes to cut costs and improve productivity. Warehouse operations are also increasingly automated, with companies leveraging AGVs, conveyors and real-time information to improve agility.

It is the continued reliance on manual loading and unloading processes that is acting as a serious constraint to efficient operations. With significant space demanded to stack goods in transit, as well as fleets of forklifts requiring both parking and charging areas, transforming this aspect of operations could deliver far more value without adding expensive space.

Automated Loading and Unloading

Replacing manual processes and minimising the use of forklift trucks with automated loading technologies radically reduces the time taken to load and unload and, as a result, allows organisations to completely redesign processes with a focus on space efficiency. The rapid movement of goods significantly reduces the volume of storage space required on site, while the reduced reliance on forklifts frees up space previously used for forklift storage and charging. With rapid turnaround of trucks, there is less need for space for lorries to park up and wait to unload or load, freeing up external space.

The potential changes are significant, with the adoption of automated trailer and container loading systems, including slipchain, moving floor and trailerskate, reducing load time from 45 minutes to under five minutes. By reducing loading bay bottlenecks, this adoption of automated loading processes is enabling organisations to double, triple, even quadruple output from the same factory. Organisations previously constrained by the physical limitations of old buildings can leverage this additional space to explore further areas of innovation, such as AGVs, without fears of forklift related accidents or the associated grime and dirt that can damage robotic technology.

Warehouse operations can be transformed, with the way space is used completely reconsidered. The options are compelling – from creating dedicated space for more effective returns handling to introducing innovative promotional packing processes to support short run, events themed marketing campaigns.

Driving Continual Improvement

Automation within the loading bay also addresses the lack of visibility associated with manual loading operations. Removing the information black hole currently constraining innovation between otherwise highly efficient manufacturing and logistics processes supports real-time decision making that can further optimise space utilisation. For example, trucks can be reallocated to different bays to maximise fill rates.

It also provides essential business agility. Organisations can seamlessly handle the expansion of SKUs associated with growth, short run promotions or new European Packaging and Packaging Waste Regulations (PPWR) without needing to expand beyond the existing footprint.

Conclusion

Pressure on warehouse and factory space is predicted to continue for the foreseeable future and the ability to achieve expansion goals without the cost, risk and upheaval associated with obtaining additional production or warehouse facilities offers immediate value for money. And, for those organisations looking to relocate in response to changing business goals or the need for more energy efficient warehouse locations to affordably meet ESG targets, there is a chance to reconsider just how much space is required and minimise costs.

By overhauling loading and unloading operations, replacing slow manual processes with highly efficient automated technologies, companies create an opportunity to reconsider space requirements to meet both current and predicted business needs. Rather than endure the constraint placed on businesses by expensive, even unavailable warehouse and production facilities, organisations can now optimise the space to prioritise production and revenue generation, and embed essential operational flexibility throughout the business.