In the push to transform supply chain agility and responsiveness, the loading bay is now under the spotlight, with organisations looking both for rapidly improved performance through automation and essential insight to join up the final component in the end-to-end supply chain management view. Wouter Satijn, explains…
Constraints of Manual Operations
Real-time data driven transparency has become a fundamental component of effective supply chain management. In an increasingly volatile global economy, immediate, trusted information is a vital requirement to enable agile, responsive operations. And with organisations throughout the supply chain increasingly exploring the power of AI to transform planning, optimisation, warehousing, transportation and asset maintenance, the need for fast access to trusted data at every stage of the process is becoming paramount.
Yet while many warehouse and production operations have achieved high levels of automation, leveraging immediate data capture through IoT and RFID to deliver real-time insight, the loading bay remains a notable blind spot. The vast majority of organisations still endure manual unloading and loading processes that are both slow and completely invisible to the rest of the supply chain operation.
The sole reliance on forklifts to move goods on and off trucks is flawed on many levels. It is dangerous, with forklift accidents remaining one of the biggest risks associated with warehouse operations. Skilled forklift drivers are also increasingly hard to recruit, creating problems in resourcing this vital task. Plus, of course, even if drivers are available and the manual process goes smoothly, it is extremely time consuming. Loading/ unloading typically takes up to 45 minutes per truck – during which time partners up and down the supply chain are completely blind to the progress being made.
Understanding Automation Requirements
This pocket of static loading bay information is an extraordinary anomaly in a supply chain that is increasingly focused on automation and real-time visibility throughout. It can constrain innovation and compromise vital responsiveness. As organisations do look to replace forklifts with automation, however, it is also important to remember this is an opportunity to do more than improve visibility to remove the supply chain blind spot. Taking the chance to radically transform the speed of loading and unloading will unlock an array of efficiency and productivity gains.
Replacing forklifts with driverless AGVs, for example, doesn’t automatically accelerate processes. While an obvious solution to problems created by a reliance on forklift trucks, AGVs aren’t necessarily faster – even when operating at peak performance. And peak performance is rarely achieved in the hazardous loading bay: AGVs need a clean environment, and the grease, oil, loose packaging, uneven floors and awkward materials that are inevitable within the loading bay cause serious problems.
Rather than swapping forklift drivers for driverless AGVs, the adoption of automated loading technologies radically reduces the time taken to load and unload from 45 minutes to under five minutes. A range of automated trailer and container loading systems, including slipchain, moving floor and trailerskate, can be deployed in sites of any size or automation sophistication, including lightweight solutions for smaller and less automated warehouses. They can be easily retrofitted to existing brownfield sites.
End-to-End Operations
Leveraging automation to provide visibility and transform the speed of loading/ unloading unlocks an array of benefits that can reach throughout the supply chain. Reduced reliance on manual labour cuts costs and safety risks. Faster loading provides opportunities to rethink processes – from reallocating certain goods to specific bays to better utilisation of existing space. In practice, organisations that have automated the loading process can significantly increase capacity within existing production facilities while also adding a new level of flexibility to support innovations such as short run promotions.
Real-time visibility provides unprecedented operational certainty at every stage of the process, building confidence that products will get to the right place at the right time. Any problems are rapidly surfaced, allowing early intervention. Trusted insight also supports the stronger relationships with transport and third-party logistics (3PL) partners required at times of global instability. It will support far more effective responses to supply chain glitches – from short term traffic problems to longer term transport challenges, such as the closure of the Strait of Hormuz – to ensure goods reach customers in the most cost-efficient way.
The ability to capture loading bay activity in real time also supports far better understanding of processes, such as issues with specific transport partners or trailer types. Combining data capture with load management unlocks opportunities to explore AI to improve predictive management.
Conclusion
Removing the loading bay blind spot through automation is a key driver for the next 12 months. It is important to remember, however, that the goal is not simply to remove forklifts and address staff shortages through automation.
Automated loading and unloading provides an essential opportunity to transform operational performance, improve productivity and gain the data capture required to deliver end to end supply chain visibility. By removing the last pocket of operational invisibility, companies can achieve the next level of integrated thinking that will support efficient and responsive, end to end supply chain integration.
