When it comes to fulfillment automation, receiving and shipping systems might look similar on the surface—scan tunnels, conveyors, labelers, sort logic—but the operational goals behind each are fundamentally different. Receiving systems are designed to capture and verify inbound inventory. Shipping systems are built to finalize and release outbound orders. Designing automation for each requires throughput equipment, tailored logic, and software integration.
Below, we break down the key differences and design considerations for receiving vs. shipping automation.
(Pictured: Receiving System Sorting to Many Store Locations)
Receiving – First Steps: Unload, Identify & Gather Data
Receiving Part 1: Rapidly unload, identify all incoming orders, while recording accurate data about all items received.
The initial goal of a receiving system will be to aid your team in unloading the truck rapidly, while scanning all items, recording the data about each one for reporting purposes. This initial induction point is critical in keeping accurate account of what SKUs are in inventory, how many, and also holding the delivery truck accountable for missed shipments.
Key challenges in the initial unloading process:
Multi-sided scan tunnels are often necessary due to unpredictable barcode placement on items coming in from the truck
Difficult-to-scan barcodes due to inconsistency – some UPC, some LPN, some inkjet while others are labels
Receiving systems need to be able to keep a count of all items received from the truck in order to match them against expected quantities
Logging scan and label data for feedback to the inventory management for delivery (truck) auditing
Receiving – Next Steps: Label, Verify, Route
Receiving Part 2: Label, Verify and Route Inbound Shipments.
The second step of a receiving system is to determine what action needs to be taken on each of the inbound items. Whether you’re unloading trailers of full cartons, mixed pallets, or individually packaged goods, the goal is to scan, label, and direct products to storage, crossdock, or staging for retail store replenishment as efficiently as possible.
For some companies, the labeling process means simply routing for a store, while others will actually weigh, dimension and manifest each product straight out to the dock in a crossdocking configuration direct to the consumer.
Other companies may simply need to put their own internal SKU tracking label on each product, and route them by product code or category.
Key actions for the receiving system:
Labeling logic for compliance vs internal routing, or crossdock manifested shipments
Exception handling – diverting all unknown, unreadable or mismatched items to QA station for individual review
Shipping – System Handoff: Scan, Label & Sort
Identify the order, gather weights, dimensions, and manifest with the carrier. Shipping automation takes over after orders are picked and packed. Systems like the Sprinter™ ensure packages are accurately scanned, labeled, and sorted to the right carrier lane based on rate-shopping and service levels.
Key features in shipping automation:
Single-sided scan tunnels with controlled label orientation
Carrier label generation via WMS, ERP, or multi-carrier software
Rate shopping and manifesting
Sortation by carrier, service level, or zone
Scanner and Labeling Design
Receiving systems need to read whatever shows up—labels on any aide, sometimes upside-down, simply due to the fact that the team unloading the truck will be moving quickly, and the varieties of product manufacturers will have barcodes in different locations on their boxes. These barcodes may be labeled, or inkjetted on. That calls for high-performance, multi-sided scanning.
Shipping, on the other hand, benefits from label consistency because the outbound process is controlled by one party, enabling faster, lower-complexity single-sided scans.
Similarly, receiving label logic varies by use case. Some cartons may need store tags, compliance labels, or shipping labels (in the case of crossdock). Outbound shipments almost always need a carrier label, triggered by LPN, order ID, or WMS handshake.
Data & System Integration
Inbound: Receiving automation often relies on pre-loaded shipment data (e.g., ASN or inbound manifest). As each item is scanned, the system verifies its identity, applies the correct label, and triggers a routing action. Real-time reconciliation helps spot discrepancies—like missing or extra cartons—early in the process.
Outbound: Shipping automation typically works off predefined orders. As soon as a carton enters the line, it’s linked to a known order. The system verifies the match, calculates shipping rates, requests a label, and routes the package to the correct carrier.
Exception Handling: Different Triggers, Same Need for Visibility
Both areas demand visibility and smart exception routing. StreamTech’s WCS enables real-time alerts, logging, and diagnostics across both systems.
Comparing Core Design Requirements:
From Receiving to Shipping: Scalable Fulfillment Starts With the Right Fit
While both receiving and shipping automation leverage scanning, labeling, and sortation technologies, their business logic diverges. One is built to ingest and validate unknown inventory; the other is engineered to confirm and dispatch customer-ready orders.
Recognizing these distinctions—and designing for them—is key to building automation that scales with your operation. Whether you’re upgrading a receiving dock or adding an outbound line like the Sprinter, StreamTech helps engineer the right fit for each phase of your fulfillment process.
The on-demand expectations of customers are increasing every day, and fulfillment warehouse operators feel this pressure more than anyone. So, when it’s time to update your systems, it can be tempting to “just get a quote” and move your project forward. But good material handling design requires time and careful planning. There really are no “instant solutions.”
To implement the most impactful fulfillment automation technology for your operation, a vendor first needs to establish a basic understanding of your business, and a detailed understanding of how orders flow through your warehouse, in a step-by-step fashion. It necessitates asking the right questions and uncovering hidden challenges. Vendors who skip these steps and jump straight to pricing often leave critical details unaddressed, leading to unnecessary change orders, unexpected expenses, and operational headaches – and often can experience huge financial losses to their business as a result.
At StreamTech, we opt for a more thoughtful intake approach that sets everyone up for smoother implementation and better long-term success.
The Value of Thorough Application Engineering Before the Proposal
In the same way highways and freeways are meticulously designed to get us from point A to point B, road development plans are not approved before and extremely thorough assessment process. The same is true for fulfillment automation: The path from raw goods to the end customer depends on a system designed to move items efficiently, but building that system requires careful consideration.
Material handling is inherently complex. It involves many variables, from the size and weight of packages to the layout of the facility, the volume of orders, the data exchange within the software stack, among others. By taking the time to collect comprehensive data upfront, automation technology vendors can design systems that align perfectly with your operation’s needs. This ensures not only a smoother implementation process but also better long-term outcomes. Vendors who don’t ask the right questions upfront and jump straight to pricing often wind up with unnecessary change orders and expenses, leaving customers to deal with the fallout.
Questions Every Warehouse Automation Systems Vendor Should Be Asking
When evaluating warehouse automation systems and comparing proposals from different vendors, it’s important to know that you’re comparing apples to apples. At first glance, one proposal might appear less expensive than another…but a closer look often reveals gaps in the information collected by the vendor. If the vendor hasn’t taken the time to understand your operation in detail, their proposal may be missing key components. While this might make their pricing look attractive upfront, those gaps will likely lead to expensive change orders later when unforeseen needs arise during the implementation process.
Some of the items that vendors may not include in their proposal may shock you: installation, commissioning, on-site training, even controls and software, support and warranty, to name a few.
The vendors asking the right questions aren’t just providing accurate pricing; they’re laying the groundwork for a solution that will perform reliably and efficiently from day one. Here are some of the essential questions every vendor should be asking to design a system that works for your unique operation:
What are your smallest and largest box sizes?
Do you handle boxes, bags, flats, padded mailers, or a combination?
What is your average daily volume, and how does that fluctuate during peak seasons?
How long is your workday, and does your operation run in shifts?
What’s the difference between a typical day and a peak-volume day?
How many pack stations are currently in use?
Where are your LPN barcodes located—left, right, top, bottom, or multiple sides?
Are any items unusually long, heavy, or difficult to handle?
Are flat items being handled, and do photoeyes need to be positioned differently to detect them?
What type of WCS (warehouse control system) connection will be required?
How long does it take to pick an order, and how many people are involved?
How many lines are typically in each order?
How many SKUs are in your inventory, and what percentage are high movers?
These final few questions are just as vital to system design. Knowing your pick rates helps right-size equipment and avoid bottlenecks or overspending. Your average lines per order determines the complexity of picking logic and cartonization. Understanding your SKU mix and fast movers ensures the system can prioritize efficiency, especially during peak demand. And your WCS requirements impact everything from scan logic to labeling to system visibility—miss this step and even the best equipment won’t deliver.
The Cost of Cutting Corners in Application Engineering Prep Work
Rushing through the initial design process or missing critical details can lead to major consequences, both operational and financial. Some examples:
Oddballs and Outliers. Let’s start with the matter of outlier items. A system designed to handle 90% of your orders efficiently may struggle with the remaining 10% if those items are unusually large, heavy, or oddly shaped. Addressing these exceptions requires a thoughtful approach—one that balances the need for efficiency with the flexibility to manage unique challenges. Skipping this step can lead to a system that’s either overengineered and inefficient or underprepared and prone to failure.
Barcode Placement. Barcode placement is another common area where oversights occur. Imagine receiving a system designed to read barcodes on one side of a box, only to find out during installation that your boxes have barcodes on multiple sides. Suddenly, you’re faced with the need for additional scanners and the associated expenses. These types of surprises can disrupt timelines, inflate budgets, and create headaches for all stakeholders.
Good Material Handling Practices. Even seemingly minor details, like the gapping of items on a conveyor, can become significant challenges. When items are placed too close together, it can interfere with essential processes like weighing, dimensioning, or labeling. To address this, systems must include conveyors that create gaps between items, a step that requires careful planning and precise engineering. Without this consideration, the entire system’s efficiency can be compromised, leading to delays and reduced throughput.
Product Packaging Profile. Finally, product packaging can also present challenges that are easy to overlook. Bagged items, for example, can be difficult to convey, label, or sort due to their irregular shapes. Whether it’s a basketball in a polybag rolling unpredictably or a pill bottle shifting within its packaging, these issues must be addressed during the design phase. Failure to do so can result in jams, labeling errors, or damaged products.
Real Results: When SteamTech’s Process Pays Off
At SteamTech, the upfront work we do is what sets our solutions apart. By taking the time to ask the right questions and understand the intricacies of your operation before finalizing your proposal, we can better ensure that your system is designed to meet your needs today and adapt to your challenges tomorrow, all while staying within budget and on schedule. After all, the success of any material handling system depends on the foundation laid during the design phase. Take these StreamTech client success stories for example:
World Wide Technology: To improve their outbound shipping process for high-value electronics, we delivered a SLAM system that accommodates a wide range of package sizes and labels while reducing errors.
DCL Logistics: For this 3PL, we created an adaptive system capable of scaling during peak demand periods, enhancing their ability to support high-growth eCommerce brands.
How We Turn Discovery Into a Deliverable You Can Trust
When it’s time to start the conversation, remember we aren’t just pricing machines. We’re designing processes tailored to your business. This takes time. Depending on complexity, our sales and application engineering process may take weeks or months and involves:
Initial calls or virtual meetings to gather information.
Requests for photos, videos, and layout drawings.
Iterative virtual meetings to refine the concept.
Site visits to finalize details.
Delivery of a fully engineered proposal.
Our thorough process ensures that when your system is installed, it works seamlessly. And if adjustments are needed, we take responsibility for making it right. By contrast, rushing this process can lead to unexpected challenges that may be difficult or costly to resolve later. Taking the time upfront allows us to deliver a solution you can trust, minimizing risk and setting your business up for success.
Hoping to get it right the first time? Let’s talk.
Since the late 1990s, eCommerce has evolved from a novelty into a dominant force in global retail, driven by advancements in secure online payment systems and logistics technology. As consumers prioritized convenience and cut back on trips to physical stores, businesses responded with more advanced e-comm stores, and increasingly automated fulfillment operations to keep pace with rising demand.
This shift has accelerated the adoption of robotics, advanced inventory management systems, and high-speed order processing, making fulfillment faster and more precise. In this post, we’ll examine the latest innovations in warehouse automation and their impact on the future of e-commerce.
What’s Driving Warehouse Fulfillment Automation in 2025
In 2025, warehouse operators must adapt to rapidly changing customer expectations and technological advancement or risk falling behind. Here are the top trends shaping the future of warehousing:
1. Robots & Their Implications On Picking Speed & Storage Density
Shelf-To-Person/Goods-To-Person Picking
The warehouse fulfillment automation industry was caught off guard in 2012 by Amazon’s acquisition of Kiva Systems for about $775M. Since then, many companies have tried to fill the gap and have developed new innovations.
As automation is expected to see more widespread use in 2025, many businesses are taking small, targeted steps to enhance their operations. Mobile shelving—also known as shelf-to-person or goods-to-person picking—is set to become more common. These robotic systems can move physical shelving within the warehouse, bringing items to the picking staff, offering a practical way to boost efficiency without overhauling entire systems.
This advanced approach utilizes automated mobile robots (AMRs) to bring inventory shelves or pallets directly to centralized picking stations. By removing the need for humans to traverse the aisles retrieving items, shelf-to-person systems “check all the boxes” for the challenges that warehouse operations professionals are looking to solve:
Reduce reliance on manual labor – Goods-to-Person robotics automate the retrieval and delivery of items, significantly decreasing the need for manual walking, lifting, and searching, allowing employees to focus on higher-value tasks.
Accelerate picking speeds – By bringing inventory directly to the operator, these systems eliminate travel time within the warehouse, enabling faster order fulfillment and reducing bottlenecks in high-demand periods. The software also slots multiple picks per rack presentation, further increasing pick speed and efficiency.
Minimize errors – With precise robotic handling and software-guided picking, the chances of human errors, such as mispicks or misplaced inventory, are greatly reduced, ensuring higher order accuracy.
Maximize storage density and efficiency – Robots travel beneath the racks, eliminating the need for aisles and allowing for a higher concentration of storage locations within the same square footage. By dynamically rearranging inventory based on demand, they further optimize vertical and horizontal space, maximizing warehouse capacity without requiring expansion.
Powered by software intelligence that directs the robots, handles the slotting of the racks according to priority, and manages the flow of orders through the system, these systems are able to increase pick speed by achieving multiple picks per rack presentation to the operator. The bots operate continuously, adapting to changing demands in real time, re-arranging the racks according to order volume and seasonality.
By taking this focused step toward automation in 2025, businesses are addressing rising order volumes and labor challenges while positioning themselves for long-term success.
2. The Power Of A Solid Warehouse Software Stack
ERP + WMS + TMS + WCS
Seamless integration between ERP, WMS, TMS and WCS software ensures real-time data flow, enabling optimized inventory management, efficient order fulfillment, cost-effective transportation, and synchronized warehouse automation for maximum operational efficiency.
Getting this software stack right is becoming increasingly important. The ERP (Enterprise Resource Planning) system centralizes business data, providing accurate inventory and order information that feeds into the WMS (Warehouse Management System) for precise stock tracking, picking, and storage optimization. The WMS then communicates with the TMS (Transportation Management System) to ensure efficient shipping decisions based on order destinations, carrier rates, and delivery timelines. The TMS works alongside the WCS (Warehouse Control System) to synchronize material handling automation, such as conveyors and sortation systems, ensuring seamless movement of goods from storage to outbound shipping.
While businesses have relied on Warehouse Management Software (WMS) for years, forward-thinking managers are now choosing software that works more precisely for their unique operations. Enter Warehouse Control Software (WCS): the brain of modern fulfillment.
Unlike WMS, which provides high-level inventory management, StreamTech’s Warehouse Control System (WCS) Software serves as the central hub of your fulfillment automation, seamlessly integrating and synchronizing various material handling systems within your warehouse.
By acting as an intermediary between hardware automation equipment, control systems, and your order database, it ensures real-time management of operations such as picking, packing, shipping, and sortation. This centralized control facilitates efficient data flow and coordination enhancing overall operational efficiency. Additionally, StreamTech’s WCS software offers real-time monitoring capabilities, providing immediate insights into system performance and potential issues, which is crucial for maintaining smooth and efficient warehouse operations. StreamTech’s WCS, for example, offers:
Real-Time Oversight: Constantly monitors equipment and processes, providing alerts and live updates for seamless operations.
Dynamic Adjustments: Adapts workflows on the fly by modifying sortation rules, updating label templates, or redirecting printer signals.
Integrated Insights: Logs every order and tracks performance metrics through dashboards and reports, helping warehouses identify inefficiencies and optimize processes.
This year we are seeing more warehouse operators seeking a solution for more stringent demand forecasting, inventory control, and supply chain transparency. Software is the answer.
3. Dimensional Accuracy: The Key To Smarter Fulfillment
For Inventory, Packaging, And Shipping
We can’t predict how the economy will shift this year. That’s why this is the year to focus on what you can control: Precise dimensional (DIM) weight measuring. While it might seem like a small detail, getting accurate measurements of your packages for shipping can have a surprisingly large impact on your bottom line.
Dimensional Accuracy In Inventory
In a fulfillment automation warehouse, dimensional accuracy is key to optimizing storage, slotting, and order processing. Precise measurements ensure the WMS allocates space efficiently, preventing wasted capacity and incorrect packing decisions. Inaccurate dimensions can lead to delays, increased costs, and potential product damage.
Cartonization and Right-Size Packaging
Cartonization selects the optimal box for an order, reducing waste, shipping costs, and packing time. Right-size packaging ensures products fit securely while minimizing material use. Automated systems improve this process, enhancing efficiency and sustainability by lowering excess packaging and shipping volume.
Advanced right-size packaging systems, such as trey erectors, random carton erectors, or robots that select the appropriate carton based on the order, take this a step further by constructing boxes to fit the exact dimensions of the items inside. These systems eliminate the need for excess void fill, reduce material costs, and optimize dimweight for shipping. With growing environmental concerns, legislation may soon require businesses to use packaging that closely matches product dimensions, pushing fulfillment centers to adopt automated right-sizing solutions to stay compliant and cost-efficient.
Dimweight For Outbound Shipping
Dimensional Weight (dimweight) affects shipping costs, as carriers charge based on volume, not just weight. Oversized boxes increase fees, making dimweight optimization crucial. Accurate dimensions and automated cartonization help minimize costs, ensuring efficienct, cost-effective shipping while maintaining package integrity.
By automating DIM weight calculations, businesses can leverage thorough data, eliminate human error, and move faster. Equipment like StreamTech’s Sprinter™ can scan, weigh, measure dimensions, and print and apply labels for between 600 and 1,000 boxes per hour, without making a mistake. This level of automation allows you to:
Reduce Costs: Optimize DIM weight to avoid overpaying carrier fees.
Avoid Chargebacks: Eliminate penalties from inaccurate or incomplete data.
Boost Efficiency: Automate processes like scanning, weighing, and labeling.
Optimize Packaging: Minimize wasted space with smarter cartonization.
In 2025, leading businesses are taking control of the aspects they can, and DIM weight automation is a simple, yet powerful, first step.
4. The Rise Of Personalized Order Experiences
Last, But Ultimately The Most Important
All of the above trends are designed to accomplish our last trend – delightful experiences for the end customer. Each year brings an increased demand for, and ability to, customize each shipment for the end customer. Personalization in packaging, shipping, and delivery is no longer a luxury—it’s a driver of customer satisfaction and loyalty. Leveraging subscription box packing software, warehouse technology, and data, businesses are enhancing the unboxing experience in 2025.
Branded packaging and personal touches, for example, create memorable unboxing moments. Right-sized packaging machinery with inkjet printing can feature logos, colors, and custom messages, while automated systems add personalized notes or full-color inserts that make customers feel valued.
Loyalty program integration takes engagement further by including QR codes or labels on packaging that link to loyalty accounts. Customers can check points, redeem rewards, and access exclusive offers. Inserts highlighting member-only events or benefits enhance exclusivity and encourage repeat purchases.
Product information inserts build trust by offering usage tips, care instructions, or brand stories within the packaging. These additions educate customers and deepen their connection to the brand.
Personalized delivery windows add convenience, especially for subscription services. By integrating advanced Transportation Management Systems (TMS) with customer data, businesses can offer flexible delivery schedules tailored to individual preferences.
In 2025, customers are no longer viewing customization as an enhancement; it’s an expected component of a meaningful customer experience.
Moving Forward With Warehousing Innovation
Warehouse fulfillment has always been a center of innovation, and in 2025, the pace will only accelerate. By embracing automation trends such as DIM weight optimization, shelf-to-person picking systems, Warehouse Control Software (WCS), and personalized order fulfillment, businesses can stay ahead in an increasingly competitive e-commerce landscape.
StreamTech is at the forefront of these innovations, helping businesses implement cutting-edge solutions tailored to their specific needs. Ready to embrace the future of warehousing? Contact us today to discuss how we can help you stay competitive and efficient in a rapidly changing market.
In warehouse fulfillment, regardless of whether the customer’s order contains car parts, jewelry, books, or medical instruments, order accuracy is the number one priority. Delivering an accurate order to every customer is the baseline for measuring success in fulfillment. It is the essential foundation upon which everything else is built. The second priority that follows closely behind accuracy is fulfillment speed. As operations ramp up with peak season or company growth, order accuracy becomes much more challenging because of the sheer volume of orders that need to be processed.
Any process involving human operators carries the risk of errors. This is the same with warehouse fulfillment operations. With manual fulfillment, orders could be picked incorrectly, contain an extra item, have the wrong label placed on the box, or be sorted to the wrong carrier.
Automation reduces errors by ensuring consistency and eliminating human mistakes. We rely on tracking orders and SKUs with unique barcodes. We track the progress of every order along the conveyor using induct verification scanners and perform parity checks at each stage of the fulfillment process. For engineered automation systems, we aim for over 99.5% accuracy, while attempting to operate at a high rate of speed (typically between 15 to 60 CPM).
Even with fulfillment automation, inaccuracies can still occur. Customers can still get the wrong items, or carriers can lose them in shipment. Without much recourse or proof other than scan data, warehouse leaders have a hard time proving they fulfilled the package accurately. But now, with unique vision camera systems we can.
Introducing StreamTech PackSight™ Camera Capture System:
StreamTech Engineering developed a camera vision system called PackSight™. The PackSight™ system does more than just capture images—it records high-resolution pictures of each completed order, whether open or sealed, as it moves along the conveyor. These images are then logged in a searchable database by the LPN (order ID).
Here are some ways this technology can enhance your operations:
Customer Service Insights: Provides data to customer service teams. In case of a complaint, operators can search the LPN database to verify whether an item was picked or not.
Carrier Accountability: Direct images of outgoing packages and contents help trace discrepancies to the carrier.
Internal Pick & Pack Auditing: Tracks accuracy in the pick and pack process using image capture and future machine vision capabilities.
Closed Box Imaging: Captures images at key stages like case sealer exit, label verification, and post-sort for damage claims.
Works well for both open box (pick audits) or sealed package (missing/damaged claims)
Images are saved to a mass storage system and indexed by scanned barcode data
Can perform binary package classification
Pairing The Image & Order Data: It’s More Than Just A Camera
You might ask, “Why not just use an IP camera to track my orders?” While a traditional camera can capture images of the items and shipping labels, the real challenge lies in organizing and tracking this data. For example, if you need to find an order labeled at 11:45 p.m. on January 3rd, you’d have to sift through hours of footage, which could include over 900 boxes if your operations runs at 15 cartons per minute. Searching through this footage wastes valuable time and effort. With PackSight™, that hassle disappears. Images are automatically linked to each order, allowing you to pull up the exact information you need in seconds. No more searching, no more guesswork.
The PackSight™ is a revolutionary system that offers more than just image capture. At StreamTech Engineering, we read the License Plate Numbers (LPNs) of each order, enabling precise tracking throughout the fulfillment process. As your order moves through each stage, the LPN is scanned and instantly communicated back to your Warehouse Management System (WMS). PackSight™ scans and logs each order by its unique LPN, giving you real-time images of open and closed cartons, as well as the shipping label details.
At StreamTech, we’re committed to enhancing efficiency and order accuracy in e-commerce fulfillment. We specialize in crafting tailored solutions that address core operational challenges, seamlessly integrating into your workflow. Through expert guidance and innovative engineering, we’ve helped countless businesses streamline their processes and improve both reliability and speed within their supply chains.
Ready to revolutionize your fulfillment process? Discover how PackSight™ can streamline your operations, improve accuracy, and elevate customer satisfaction.
Connects a variety of different technologies together, from different manufacturers
Integrates the technologies to work cohesively, intelligently, and safely
Why:
No equipment manufacturer can provide everything you need – they specialize
Integrators have a broad, unbiased expertise across a wide range of technologies
We’ve written software that makes your system smarter
You don’t have to do it alone – we’ve seen some things and can offer helpful advice and ideas to make your automation smarter
Keep pace with changing technology and growing customer demands
Fulfillment Automation Integrators Are Material Handling Technology Experts
Are you looking at updating your distribution warehouse to improve material flow and increase productivity? If so, there is a wide range of technologies to explore, and once you begin to get an understanding of the types of systems you have a need for, you should then reach out to a systems integrator to help.
Why? Designing a successful material handling system requires the integration of a wide range of specialized technologies, from a number of different manufacturers. Scales, dimensioners, scanners, conveyors, control panels, photo-eyes, printer applicators, diverters, lights, alarms, sensors, robots, vertical lift modules, case erectors, baggers, tapers, palletizers, document inserters, and software – all these technologies have to work together in concert to create a successful fulfillment automation integrator system.
Each of these technologies is developed by companies that are highly specialized in each of their own areas of expertise, to develop the best products in their category. There is no manufacturer who makes every device necessary for your warehouse, and none that will connect them all.
A Material Handling Systems Integrator Is Able To Provide Unbiased Advice On What Technologies Are Best Suited For Your Business’s Challenges, Goals, And Product Details
The role of a material handling systems integrator is to manage the design, equipment, and installation of a cohesive material handling automation system. A systems integrator consults with clients to understand their facilities and business needs and designs a system with a wide variety of interconnected, specialized technologies that meet those needs.
The systems integrator will design and implement a customized solution based on your specific requirements, to meet your goals. They’ll recommend trustworthy brands and equipment that works well with others, and will efficiently process the types of items your warehouse handles.
You’ll Need Warehouse Control System (WCS) Software To Interface With The Hardware, And The Best Integrators Have Developed Their Own
An effective material handling system requires communication on both a hardware and software level as well. Today’s warehouses run on a software to manage things like inventory, orders, transportation, receiving, replenishment, manifesting, sortation, and more. Understanding how the equipment will send and receive data between all of these software tools is critical.
The best fulfillment automation integrators have developed their own in-house software to manage these connections between hardware and software. This is called the Warehouse Control System (WCS) software. It should be able to handle the hardware handshakes between equipment such as conveyors, scanners, scales, printers, and control panels, and should also be able to communicate with the ERP, WMS, multi-carrier, and other software platforms.
A Warehouse Control System (WCS) is a real-time, integrated control solution that manages the flow of items through the warehouse. They act as a traffic regulator for warehousing activities, with the mission of running material handling systems (and in some instances, the activities of workers). A good WCS system provides a broad, yet consistent interface for material handling systems like conveyors, carousels, palletizers, sorters, etc.
Key WCS Functions:
WCS manages the operations of many types of material-handling equipment
WCS exchanges real-time communication of information
WCS can synchronize the operation of automated systems, labor, and material
WCS unifies the interface and control of automated equipment
WCS focuses on one warehouse at a time
Material Handling Systems Integrators Help Avoid Common Pitfalls And Recommend Best Practices.
With experience developing material handling solutions for a wide range of industries including eCommerce fulfillment, manufacturing, retail distribution centers, third-party logistics providers (3PLs), and more, a material handling systems integrator will work with you to develop the best solution for your specific business needs.
The systems integrator plays a key role as the link between different technologies, the warehouse operator’s goals, and material details. Getting any piece of this equation wrong would likely produce a worse result than before.
Keep Pace With Ongoing Technological Changes With Integrated Warehouse Systems
Technology changes, business requirements change, and the expectations of the warehouse will change over time, and integrators help companies keep their systems relevant. Integrators also help companies make better use of their space by identifying opportunities for automation, or performance-based solutions as they become available. Integrators are often involved with implementing new warehouse management software and technologies that can be used to reduce costs while improving service levels to customers.
The fulfillment area of your warehouse is comprised of a variety of functions, from inventory receiving and replenishment, to picking, packaging, transporting, shipping, sortation, and more. All of these discrete areas of the warehouse have a wide range of requirements, inputs, and outputs, as well as nuances based on the type of products and customers involved. These nuances all have to be managed by a central software that handles the hand-off between all of these various systems and the software databases that also manage each of these systems.
A WCS Warehouse Control System is a real-time, integrated control solution that manages the flow of items through the warehouse. They act as a traffic regulator for warehousing activities, with the mission of running material handling systems (and in some instances, the activities of workers). A good WCS system provides a broad, yet consistent interface for material handling systems like conveyors, carousels, palletizers, sorters, etc. This can result in great ROI for warehouses.
Key WCS Functions:
WCS manages the operations of many types of material handling equipment
WCS exchanges real-time communication of information
WCS can synchronize the operation of automated systems, labor, and material
WCS unifies the interface and control of automated equipment
WCS focuses on one warehouse at a time
WCS sits in a layer that connects directly to automated equipment. It adjusts at the level of a single piece of equipment — and often through an entire facility. It can modify the behavior of shipping systems, conveyors, sortation, pick and pack automation systems, etc. WCS may also be integrated into wider essential systems to streamline warehouse management operations. For example, security devices like dome cameras, alarms, and access control systems may send real-time data to WCS, enabling stakeholders to receive automated alerts regarding security incidents.
If your warehouse were like a smart home – you have blinds, doorbells, cameras, garage doors, water sensors, light switches, TV’s, speakers. Would you rather have multiple apps on your phone to control every single one of these devices, or would you rather have one app where they’re all organized and controlled? This central control is the WCS for your warehouse.
See StreamTech’s WCS Software:
What Software Connections Does It Make?
A successful automation system is about more than just hardware. Yes, the WCS manages picking, packaging, shipping and sortation equipment from a variety of different manufacturers, orchestrated perfectly together to meet your daily business requirements. However, in this digital age, we cannot overlook the software and database connections that the WCS must also make, to your WMS, ERP, order management and/or multi-carrier platform.
In a fulfillment automation application, in order for the hardware to perform tasks such as assigning weight, dimension data, pick status, packslip status, sort location or other information to an order, it must be connected to your multi-carrier or order management software. The connection to these platforms allows the data to be powerful enough to do things like rate shopping in real-time from the weight and dimension data, perform address verification, proof of delivery, and other important functions for your company and ultimately your customers. Read this excellent article from MHI’s Warehouse Automation Blog on other warehouse software, and how the WCS fits together.
What WCS Capabilities Should You Expect?
When looking at fulfillment automation integration partners, choose one who has a warehouse control software that is robust, proven, and that you can trust with your physical hardware and data. A warehouse control system (WCS) directs “real-time” activities within warehouses and distribution centers. They act as a traffic regulator for warehousing activities, with the mission of running material handling systems (and in some instances, the activities of workers). A good WCS system provides a broad, yet consistent interface for material handling systems like conveyors, carousels, palletizers, sorters, etc.
Interface to HMI’s, can be shown directly within the software application
Built-in browser, interfaces to any web-connected hardware
Defined user roles – administrator vs. operator
Built-in hardware troubleshooting test functions (test labels for printheads, boundary, other testing)
Search by order, LPN, tracking number, category, status, lane etc.
If you are a warehouse worker or someone seeking warehouse job options, it’s crucial to be aware of Warehouse Control Systems (WCS), as they greatly enhance efficiency and organization within the warehouse environment.
StreamTech’s engineering and software development teams are constantly researching and incorporating new features to increase the capability of our WCS. For more information, or if you would like to discuss your fulfillment operation with us, please fill out the form below or give us a call.
“Like any company that blissfully ignored the Internet at the turn of the century, the ones that dismiss the Internet of Things risk getting left behind.” —Fast Company
Internet of Things (IOT) technology is transforming ways in which automation systems are installed, and maintained — and the way customers can tap in to maximize their value. Whether you are evaluating more fulfillment automation technology for your operation or DC, or have already made a recent investment – be sure to understand and leverage the value to help reduce costs, increase throughput, and better understand your business.
Commissioning Times Are Being Slashed
To generate value, today’s systems typically contain a wide variety of technologies – labeling, conveyors, scales, machine vision, dimensioners, and warehouse control system software. But implementing these systems no longer requires an onsite army of specific experts. Now, the commissioning technicians can be supported virtually: Developers, Scanner Experts, Controls Engineers, and Scale Technicians, for example. The customer gets the benefit of multiple resources all working in parallel with reduced travel expenses. An individual team member can be tapped briefly and fluidly for specific knowledge. All of this combines to help you get your system up quicker and at a lower cost.
Intermittent Problems Are Solved Quickly
Ever had a car with a problem that seemed to hide while at the dealer? Me too!! In our industry, it’s the bug that disappears when we are watching onsite or remotely. StreamTech creates virtual ‘robots’ that monitor input and communications data to flush out and resolve those once-in-while problems. This may take the form of a machine vision system monitoring label placement or a process that looks for intermittent communication losses. Either way, it’s a lot more fun and cheaper than waiting and watching.
Systems Are Maintaining Themselves
As customer requirements become more demanding, we continue to add clever ways to save customer maintenance and operational resources. The proliferating number of sensors means that the systems can self-diagnose to save resources:
Labelers request more labels; turn themselves off while their siblings pick up the load.
Areas of the system are de-energized automatically when not in use
Electrical and compressed air utilities are monitored and the system compensates or stops when parameters are out of bounds.
Auto-request of print heads when scan rates start to decline
The system asks for a routine check of a drive roller with a higher-than-normal current.
Smart Exception Management – identifying if it’s a random event, or indicative of a sudden problem.
Rich Data Streams Are Available And Readily Mined For Insight
StreamTech monitors and displays a wide variety of statistical and operational data for consumption through our standard and customized reports. Reviewing this data provides insight into both the system’s health and how your business operates. This data can be promulgated to your senior managers’ desks through remote StreamTech workstations, or captured of the data into your in-house systems. Studying this data can allow you to extend the life of your system by optimizing its peak periods and how to best operate the system for maximum throughput and efficiency.
Order Fulfillment IOT Takeaways:
Purchase Evaluation: How does the proposed system include connectivity that can be leveraged to reduce cost and increase functionality? What’s available as a standard?
Implementation: Maintenance and users understand how to leverage intelligence in the system to reduce downtime, and anticipate service.
Operational/Ongoing: Ensure system generated data conveniently available and summarized so it can be promulgated and re-purposed. Management engagement and use in planning.
