With what appears to be ever increasing demand and supply chain dynamics, and the perceived inflexibility, some might say the future for automated material handling systems in distribution is not bright.
The reality is, the authors says, is that the setup, adoption and usage of material handling automation must ultimately be so simple that new automated systems can compete in flexibility, adaptability, and reusability with non-automated systems.
In order to achieve this goal, the authors say, automated systems must have properties similar to those commonly found in the “Plug & Play” approach found today in most consumer electronics systems, in which components can be easily added, swapped out and reconfigured over time as technology evolves.
To achieve that level of flexibility, next generaton material handling systems must achieve the following attributes and capabilities, the authors say:
 Plug & Play Design: Once the system is physically installed and commissioned, and everything is done, new components, which are equipped with quick disconnect devices, are added by simple insertion. In order to achieve high system reliability, failing components must be easily replaced, and must not require resetting the whole system. The system detects and/or predicts its own failures and then reconfigures itself after new components have been inserted.
We'll note that hile this capability has recently become available for applications involving Motor Driven Roller conveyor (MDR), it is not universally available for conventional powered belt and roller conveyors, which are in common use.
It is understood that this capability may not apply to all devices, especially those that operate on high voltage and/or draw high amperage. However, they represent a very small percentage of the 1000s of replaceable devices, components, and modules included in the typical system.
Scalability: The scope and/or physical size of the system can be easily adjusted up or down in order to adapt to changing performance requirements. The ability to start small and easily insert additional capacity as needed, and/or remove pieces of automation that are no longer needed.
Re-Configurability: The user/operators must be able to change the physical arrangement of equipment themselves, without the help of electricians or programmers. Changing the systems configuration must be possible within minutes, or at most a few hours. This would be similar to a LEGO-like building approach - long a user vision for material handling systems.
Self-Adaptability: The system should be able to adapt to changes in the patterns and quantities of the material flow. Ideally, the system would detect these changes in flow and be able to adapt itself accordingly.
We'll note here that Dematic (supplier of logistics systems for the factory, warehouse and distribution center), has recently introduced has introduced what it calls "Automatic Speed Control," a new control solution that automatically adjusts the speed of the entire sortation system from merge through the sorter take-away conveyors to accommodate actual throughput volume going through the system. Many other providers offer manually adjustable speed controls.
 Modularity: The system should consist of highly independent modules and sub-systems, which supplement each other in order to perform the material handling tasks. The modules can be combined easily in order to create an integrated system. Once installed the links between the modules are established by the modules themselves.
Function Integration: Each module and/or sub-system contains all intelligence necessary to perform its task. This usually includes, but is not limited to, identifying loads to be moved and/or sorted, accumulate and/or release loads as required, recognizing the conditions of surrounding modules, and pass appropriate real-time information to surrounding modules and/or sub-systems.
Decentralized Control: The actions of the modules are controlled by their own controllers. Adjacent modules freely exchange information in real-time relative to the movement of goods. With the exception of the WMS/WCS, there is no central or master module(s) that all information must flow through.
Standardized Physical and Information Interfaces: A major obstacle for reconfiguring automated systems is the need to synchronize functionality of sensors, drives, controllers and mechanical components. Automated systems should be able to exchange information on a function-based level, thus avoiding the problem of synchronizing parts of the system. This capability is made easier today due to the existence of network communications standards such as EtherNet, Profibus, and DeviceNet networks.
Inherent Safety: Automated system functions like storage, transportation, picking and sorting must never damage goods or endanger the people around it.
Resource Efficient: Reduced energy consumption by only activating those modules that are required at any particular time.
 Cost Verses Benefit
Such a flexible automation world sounds great, doesn't it? But can such a flexible solution really be delivered at a reasonable costs?
"No doubt a modular/component-based, Plug & Play system is likely to be more expensive than current material handling systems because more technology is used in each module," say Gue, Furmans and Schönung. "But to dismiss the concept on the basis of cost is to miss the point that a major objection to adopting automated material handling systems is inflexibility, not high cost. Plug & Play systems offer a way to overcome this objection."
They add that there are several reasons to be optimistics that this level of system flexibility can be affordably in the near future. Those reasons include: |
