How integrated control systems can future-proof warehouse logistics

Consumers demand seamless shopping experiences across online, in-store and mobile platforms, so warehouses must adapt to manage inventory and orders from multiple channels efficiently. Stephen Hayes explains the role of advanced automation in helping warehouses achieve seamless fulfilment across all sales channels

Today, many consumers demand convenience and flexibility – and retailers have had to adapt their strategies in response. When customers shop, they now use everything from traditional brick-and-mortar stores to social media and mobile apps to purchase the goods they need – and they expect a connected journey with consistent, personalised interactions. 

Omnichannel is a blueprint for the future of the industry, that is according to a recent study from digital insights firm Incisive. The report found that a staggering 73% of retail transactions involve a digital touchpoint, underscoring the hybrid nature of modern shopping behaviours. Retailers have made headway in establishing digital platforms and an online presence and, to achieve a strong omnichannel experience, they should focus on their warehouse workflow. This means replacing manual and analogue systems with more automated and integrated systems, such as PC- and EtherCAT-based control technologies. 

The future is automated 

Futureproofing warehousing and logistics is key for meeting this omnichannel demand, but this means more than just automating one or two processes. The key is automating and connecting each process and piece of equipment so that they can be controlled and adjusted with speed and ease, by operators on the warehouse floor or complex algorithms in the future.

Conveyer systems, for example, have helped automate linear product handling for decades – and are crucial for delivering seamless fulfilment. Over the years, this technology has become more efficient and overcome issues such as product backpressure by using multi-zoned conveying systems. These systems can allow for zero-pressure accumulation (ZPA), avoiding potential damage or defects in products.

Controlling each motor in a multi-zoned conveyor is vital for efficient product traffic, best achieved by using a unified platform that ensures quick data communication and consistent motor control across all motion applications.

To address this, Beckhoff recently launched the EP7402 EtherCAT box, a motor-driven roller (MDR) conveyor system controller that integrates with the widely-used TwinCAT 3 automation software. This allows diagnostic data from the controllers to be transmitted to TwinCAT Analytics, enabling remote monitoring and predictive maintenance.

An integrated control platform 

As more retailers move to an omnichannel model, this will mean adopting automated, AI-driven and integrated technologies in their warehouses. With this, they must invest in the necessary control systems to help regulate the timing, control and sequencing of processes, machines, and entire production lines. Control systems can also help retailers collect real-time data, such as from sensors, which support predictive maintenance and help maintain uptime. 

However, retailers face a catch-22. Control systems are essential for omnichannel operations, but traditional programmable logic controllers (PLCs) – common in most warehouses – cannot keep pace with more intelligent, data-rich systems. For example, machine learning is vital for machine optimisation, but PLCs will struggle to support such a system.

Consequently, as omnichannel reshapes warehouse operations, retailers should look at installing PC-based control technology, which can support these more advanced systems because they come equipped with the necessary software features and network capabilities. The benefits of PC-based controls are many. For example, Beckhoff’s PC-based controls offer improved performance thanks to their multi-core processors, they support integrated cloud connection, and they offer good scalability. Furthermore, they are compatible with EtherCAT and other common fieldbus systems.

Omnichannel retail has been a game-changer, transforming the shopping experience across online, in-store and mobile platforms. As more retailers jump on the omnichannel bandwagon, they must consider the automation processes in their warehouses and the integrated systems they will need to achieve seamless fulfilment.  

Stephen Hayes is managing director of automation and control technology specialist Beckhoff.