The 5 Levels of Automation in Intralogistics

05:00 minutes reading time

By automating your intralogistics, you optimize your processes and raise efficiency. But how much automation is right for your business? In this blog post, we introduce you to the different degrees of automation: from a completely manual warehouse using intelligent software to the fully automatic manufacturing of the future. Discover more.

Key Takeaways

  • Automation does the heavy lifting for personnel, ensuring efficient processes as well as transparent decision-making.
  • Technologies such as conveyor systems, automated storage and retrieval systems, driverless truck systems, robotics, software and AI provide companies with much-needed support for their intralogistics.
  • How the 5 levels of automation differ: from a manual to a fully automatic warehouse.
  • Best practice examples from Jerich, Fronius, Magna, Getriebebau NORD and Würth demonstrate the different levels of automation and the right automation technologies for every application.
  • With solutions from KNAPP, you’ll find the right degree of automation for your logistics and stay competitive.

The call for more efficient intralogistics

Intralogistics plays an important role in the profitability of a company and includes all the processes and systems involved in the internal transport, storage and order processing of goods and materials. With rising cost pressure, skilled labor shortages as well as technological progress, automation for intralogistics is becoming increasingly important. That’s because the new challenges call for a more flexible and efficient design of storage and transport processes. In this context, let’s take a closer look at the advantages of automation solutions before we go into the various technologies and stages.

The advantages of automation

Automating intralogistics offers companies many opportunities to increase efficiency and stay competitive. Here are the most important advantages:

Personnel allocation for value creation
Automation does the heavy lifting as well as the boring dangerous tasks. People can then work at other tasks, to generate value.
Increased efficiency
Automation systems work with greater speed and more precision, raising quality, process reliability and manufacturing speed.
Lower costs
Although the initial investment in an automated system can be high, over the long run, it ultimately saves money by reducing labor costs, errors and by optimizing processes.
Data analysis
Automated systems generate much needed data, which companies can use in making decisions. Bottlenecks in process can be detected early on, and maintenance can be planned for just the right time.

Automation technologies

Intralogistics systems are automated using a variety of innovative technologies:

Conveyor systems
connect various storage and manufacturing areas
Automated storage and retrieval systems
efficiently store goods and facilitate order processing
Driverless truck systems
carry out internal transport jobs without manual control
Robots
carry out tasks such as picking, packing and palletizing
Intelligent software and AI
optimize processes, enable transparent decision-making and make forecasts
The graphic shows the AeroBot warehouse robot moving vertically in the warehouse

Our comprehensive KNAPP portfolio means we can offer customized automation solutions for every requirement. Our portfolio ranges from simple stacker cranes to innovative storage and transport robotics and highly efficient storage and retrieval systems. Our intelligent software rounds out what we offer as a supplier of complete solutions.

Find out more >

Automation in intralogistics from 0 – 100 %

What form does automation take in today’s intralogistics? Depending on the requirements and goals, automation can be used in many different ways, from semi-automation where humans work side-by-side with machines to full automation where processes are carried out with little to no human intervention. Let’s take a closer look at the possibilities for the varying degrees of automation.

The graphics depict the five levels of automation in intralogistics from zero, 25, 50, 75 to 100 percent.
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automation

No automation: a manual warehouse with intelligent software

Automation in intralogistics is often associated with large warehouse solutions and a lot of technology. For smaller companies, this is likely too much automation and too great an investment. A high-tech warehouse is not always the solution. With innovative software and ergonomic work stations, individual processes and existing steps in production can be efficiently and intelligently designed and optimized.

Best practice at Jerich International:
work station with integrated image processing system

At Jerich International, quality checks are made on vehicle body parts at a state-of-the-art work station equipped with an integrated image processing system. The Vision Smartdesk helps personnel to check the parts. The actual images are compared with expected images. Thanks to real-time feedback, quality deficiencies are immediately pointed out, and personnel are given optimal support while working.

A person is pressing a button at a work station. In front of her is a monitor and a part of a gearbox.
The Vision Smartdesk gives employees feedback in real time regarding the accuracy of each work step, to prevent errors. The work steps are also fully documented, which avoids error corrections and the cost of returns by up to 100 %.
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25 % automation: manual warehouse and automated transport processes

A great first step in automation is using an autonomous mobile robot (AMR) to handle internal transport jobs. These robots connect individual locations with each other and ensure the flow of goods. Automating transport makes sense and allows personnel to concentrate on value creation instead of pushing around heavy boxes. The required parts are supplied to the work stations and production lines just-in-time. What’s more, an automated guided vehicle system can easily be integrated into existing structures.

Best practice at Fronius:
AMR automates transport processes

Fronius, a worldwide leader in welding, battery charging and photovoltaic systems is using Open Shuttles for internal transport. The Open Shuttle Fork, an autonomous mobile robot for pallet transport, connects the goods-in and goods-out areas with the production cells and supplies them automatically with goods. Even where there is a lot of traffic, these AMRs navigate safely through the halls. The space-effective transport solution was implemented without having to make changes to the existing infrastructure. Thanks to the intelligent fleet control software KiSoft FCS, Fronius can make changes on their own.

Three autonomous mobile robots are moving through a warehouse, one transporting cartons on a pallet.
16 Open Shuttle Fork robots handle transport jobs of all kinds at Fronius. They form the link between goods-in, the production cells and goods-out.
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50 % automation: automated small parts warehouse (ASRS) and ergonomic work stations

If what matters is high-performance and space-saving storage of small parts, along with supplying work stations quickly and efficiently, then it is worth investing in an automated storage system. Companies have many possibilities here: from a simple stacker crane system to innovative warehouse robotics to shuttle systems. Here, the storage system is connected directly to modern work stations for goods-in, goods-out, assembly and picking processes. An intelligent warehouse management system controls and monitors the processes centrally. Our blog “Shuttle vs Bots: Which Storage Technology is the Better Choice? goes in depth on this topic.

Best practice at Getriebebau NORD:
warehouse automation for efficient processes

The automated small parts warehouse Evo Shuttle supports the logistics hub of Getriebebau NORD in Bargteheide, Germany, helping to supply materials worldwide as well as to production and the onsite storage facilities. Through the software KiSoft One, NORD controls and monitors the processes. The ergonomic work stations of the “Pick-it-Easy” series support personnel in goods-in as well as in picking. In goods-out, modern packing stations are available for shipping. The storage system is connected to the work stations through the conveyor system. Thanks to its optimal use of space and efficient processes, the solution is a winner.

Close-up of two shuttles by KNAPP in a small parts warehouse.
At Getriebebau NORD, all small parts are stored centrally in the Evo Shuttle and are retrieved when needed for picking or packing. Thanks to its optimal use of space and efficient processes, the solution is a winner.
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75 % automation: innovative logistics solution knows all the tricks

The higher the degree of automation, the more areas and processes are connected with each other and covered by innovative technologies. At the center is an automated storage system with ergonomic work stations and direct connection to autonomous mobile robots or tugger trains. The software has a major role to play while assistance and image processing programs make an innovative add-on.

Best practice at Magna Assamstadt:
innovative logistics solution for production supply

Magna, one of the world’s largest automotive suppliers, invested in a comprehensive automation solution at their Assamstadt, Germany, location in order to increase their real net output ratio. The company relies on the automatic small parts system Evo Shuttle in combination with the Open Shuttle autonomous mobile robots for their intralogistics. Multifunctional work stations are directly connected to the storage system and are supplied with goods just-in-time and just-in-sequence. Transport orders between the storage system and the production lines in the adjacent halls are handled by the Open Shuttles. The highly modern automation solution ensures efficient and flexible production processes.

Two autonomous mobile robots are moving in front of a conveyor system, a storage system and work stations.
Magna stores mirror parts and empty containers centrally in the Evo Shuttle, which are later retrieved as needed for manufacturing or assembly. Six Open Shuttles connect directly to the small parts warehouse.
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100 % automation: fully automated intralogistics

Fully automated logistics does not mean a warehouse devoid of human beings. What it really means is a warehouse full of technologies, where humans and machines work closely together. This includes the warehousing, transport, picking and packing of goods. By using robots, autonomous vehicles and intelligent software solutions, processes can be almost completely automated. Everything is coordinated like clockwork for efficient, fast, and error-free operation. As a result, large quantities of data are generated, which must be optimally used as well.

Read more about it in our blog Smart Manufacturing: The Future of Production.

Best practice at Würth:
smart production ensures optimal processes

The automation solution at Würth Industrie Service includes an all-round intelligent package of technologies and software. The company relies on several picking robots, the Pick-it-Easy Robots, to handle the rapid picking and in shipping, to do the palletizing. The Open Shuttles handle all the internal transport processes fully automatically. The Evo Shuttle storage systems handle all the storage, consolidation, sequencing, dispatch buffering and picking processes. A Fastbox sequences orders quickly and accurately. Order processing is carried out according to the goods-to-person principle at the numerous multifunctional work stations. A comprehensive software solution allows the individual processes to be integrated into a network for intelligent automation. Data is analyzed using an analytics tool from which optimization steps are derived with respect to system operation and maintenance. Perfect, complete automation.

Intralogistics automation by a Pick-it-Easy Robot picking up items from a container on a conveyor line.
Würth’s Pick-it-Easy Robot by KNAPP reliably makes up to 300 picks per hour making fully automatic picking a reality.

Conclusion and outlook

In the future, intralogistics automation will be indispensable for boosting competitiveness. The earlier companies get going with new and innovative technologies, the better they will be able to keep pace with the rapid developments in this area. Technological advances, whether they come in the form of innovative warehouse robotics or artificial intelligence, bring more efficiency and flexibility to warehousing and manufacturing processes. The key to success for every company, however, lies in a well thought-through strategy which considers the right degree of automation and the right technologies.

Would you like to know more about our solutions for automating intralogistics? We’re happy to tell you all about it!
05:00 minutes reading time
Stefanie Terler
Stefanie Terler
Communications & PR
Industry Solutions
What trends and challenges are shaping the manufacturing industry? What are the smart ways to automate this industry? Stefanie blogs about and researches these topics for you.

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Additional Information

Let’s talk about what the optimal level of automation would be for your logistics processes. Just drop us a line at blog@knapp.com.