Automation allows a truck to be unloaded in ten minutes. That is a substantial time gain compared to the 45 minutes the manual process takes. That is one of the conclusions from research by the Flemish Institute for Logistics (VIL) into automated loading and unloading solutions.
The OptiCharge project, in which 13 companies participated, concerns a market study on state-of-the-art loading and unloading systems. VIL and the University of Antwerp investigated how loading and unloading can be made more efficient for both shippers (warehouse staff) and carriers (drivers).
The systems tested can be divided into three types: Automated Guided Vehicle or AGV-based systems (industrial robots that propel themselves autonomously), one-shot-based systems (which load/unload an entire load in and out of the trailer at once), and semi-automated systems (where human interaction cannot be completely omitted). The latter option is particularly interesting for goods with a different shape.
The results show that each technology has its own advantages and disadvantages and no single system can be touted for handling every type of cargo. The company-specific context in the warehouse also helps determine whether the intended implementation is practically feasible.
From 45 to 10 minutes
At chocolate manufacturer Barry Callebaut, a successful business case was run with the one-shot-based skating system. Through the system, 26 pallets were unloaded automatically in 10 minutes, without a hitch or damage. This resulted in a significant time saving compared to the 45 minutes that manual unloading currently takes. A conveyor system with chains and a roller conveyor could deliver even greater time savings, VIL argues. But as this system was not available during the duration of the project, it could not be tested in practice.
Automation solution for every load
VIL concludes that the project demonstrates that there is an automation solution for every type of cargo and warehouse. The majority of participating companies reportedly intend to take the knowledge gained further.
"There is a lot of potential and this project has provided us with the necessary insights for future improvements in our warehouses," says Jan De Winter, Distribution Manager at nappy manufacturer Ontex. "The practical approach and elaboration of the project have also taught us not to proceed overnight. There is a certain complexity present that we have to face. The potential is definitely there, it is now up to us, with data and info obtained, to responsibly start and work out a project."
