Category: Warehouse Management System

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5 Signs It’s Time to Upgrade Your Warehouse Management System

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5 Signs It’s Time to Upgrade Your Warehouse Management System

A warehouse management system (WMS) is the foundation of efficient distribution and manufacturing operations. It directs inventory, guides workflows, and ensures products move smoothly from receiving to shipping. However, not all WMS platforms are created equal, and even the best systems eventually reach a point where they no longer meet the demands of a growing business.

At Ascent Warehouse Logistics, we have seen how the right WMS can transform accuracy, labor efficiency, and throughput. We have also seen the challenges companies face when they try to push outdated systems beyond their limits. Here are five clear signs that it may be time for your organization to consider an upgrade.

5 Warning Signs Your WMS Can No Longer Keep Up

1. Inventory Accuracy is Slipping

If your inventory accuracy consistently falls below 99.5 percent, it is a red flag that your WMS is not keeping pace with operational demands. Inaccurate inventory leads to missed shipments, delayed orders, and costly rework. Modern WMS platforms track inventory by location in real time and manage replenishments across multiple location types such as pick faces, overstock, and dynamic locations. The result is stronger visibility, higher customer satisfaction, and reduced carrying costs.

2. Labor Costs Are Rising Faster Than Revenue

Warehousing is labor-intensive, and labor costs continue to increase with mandated wage hikes and rising healthcare expenses. If your labor costs are growing disproportionately to revenue and order volume, it is time to evaluate whether your WMS is directing work efficiently. A modern system can guide operators through optimized picking paths, integrate with automation, and reduce wasted movement. These capabilities can cut labor costs by 25 to 50 percent without sacrificing accuracy or throughput.

3. Customer Expectations Are Outpacing Your Capabilities

Today’s customers expect speed, flexibility, and precision. If your warehouse struggles to keep up with e-commerce order profiles, omnichannel fulfillment, or just-in-time delivery, your WMS may be holding you back. Modern platforms support order profiling, batch and cluster picking, zone picking, and seamless integration with automation technologies such as voice picking, pick to light, carousels, and autonomous mobile robots. These capabilities are critical for meeting modern fulfillment requirements without overburdening staff.

4. Integration with Enterprise Systems Is Limited

A WMS must integrate seamlessly with ERP, order management, and other enterprise systems. If your current platform creates isolated silos of data, requires manual workarounds, or struggles to interface with automation hardware, the inefficiencies will compound over time. Best-of-breed WMS solutions not only integrate with ERP but also provide warehouse control and execution capabilities in a single system, eliminating the need for multiple vendors and layers of software.

5. Expansion Feels Risky or Unattainable

If launching a new product line or opening a new distribution center feels overwhelming because of system limitations, your WMS is no longer serving as a growth enabler. A modern WMS should give you the confidence to expand with scalability built in. Whether you are adding users, zones, or new workflows, the right system scales with your business and allows you to deploy new operations quickly and effectively.

Strengthening Your Future with Ascent

Recognizing these signs is the first step toward building a stronger warehouse operation. Upgrading to a modern WMS is not just about fixing problems. It is about unlocking opportunities for growth, reducing business risk, and ensuring you are prepared for the demands of tomorrow’s supply chain.

At Ascent Warehouse Logistics, we deliver WMS solutions that improve accuracy, optimize labor, and integrate with advanced automation. Our proven track record of successful implementations provides the confidence that your investment will deliver measurable results.
If you see any of these five signs in your warehouse, it may be time to evaluate your next step. Contact AscentWL to learn how our solutions can help you achieve higher accuracy, lower costs, and a stronger competitive position.

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The Essential Guide to ERP vs WMS for Modern Warehouses

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The Essential Guide to ERP vs WMS for Modern Warehouses

In today’s fast-moving supply chain world, software is the backbone of efficiency. Two of the most widely used systems are Enterprise Resource Planning (ERP) and Warehouse Management Systems (WMS). While the acronyms are familiar, the differences between these platforms are often misunderstood. Many businesses mistakenly believe an ERP can fully manage warehouse operations, only to discover the limitations once accuracy issues, labor costs, or order delays start to pile up.

At Ascent Warehouse Logistics, we’ve seen firsthand how important it is to know the distinction between ERP and WMS solutions. Understanding where each one excels will help you decide which system best supports your business goals.

What is ERP?

Enterprise Resource Planning (ERP) systems are designed to integrate and streamline an organization’s core business processes. Think of ERP as the central nervous system for the enterprise. Common ERP modules include:

  • Finance and accounting
  • Human resources
  • Procurement
  • Customer relationship management (CRM)
  • Manufacturing planning

ERP systems provide visibility across the organization, helping leaders make better decisions and align business functions. They are powerful tools for managing the “big picture” of operations. However, when it comes to the granular, real-time needs of warehouse execution, ERP systems often fall short.

What is WMS?

A Warehouse Management System (WMS) is built specifically to optimize the day-to-day operations inside warehouses and distribution centers. Rather than focusing on high-level business processes, a WMS zooms in on inventory movement and order fulfillment. Core functions include:

  • Receiving and putaway
  • Inventory location management
  • Picking, replenishment, and packing
  • Shipping and manifesting
  • Real-time inventory accuracy

Where ERP systems tend to track data at a summary level, WMS systems are engineered to direct warehouse staff, automate workflows, and ensure that every product is in the right place at the right time. This operational focus drives measurable gains in productivity, accuracy, and cost control.

ERP vs. WMS: Key Differences

Although ERP and WMS platforms share the goal of improving efficiency and reducing costs, they approach the problem from different perspectives.

Functionality: ERP handles enterprise-wide processes, while WMS focuses on warehouse execution.

Complexity: ERP implementations are broad and often complex, requiring significant time and investment. WMS systems, on the other hand, are more specialized and user-friendly for warehouse teams.

Accuracy: A WMS can achieve 99.5%+ inventory and order accuracy, reducing costly errors that ERPs are not built to manage at the same level.

Labor Impact: By directing tasks and integrating with automation, WMS reduces reliance on manual entry and lowers labor costs by 25–50% in many cases.

Scalability: ERPs are excellent for enterprise growth, but WMS offers the operational scalability warehouses need when SKU counts, order volumes, or customer expectations increase.

Which One Do You Need?

The choice between ERP and WMS depends on your priorities:

  • If you need enterprise-wide visibility across finance, HR, and manufacturing, ERP is essential.
  • If your challenges center around fulfillment accuracy, warehouse productivity, and labor costs, a WMS is the right fit.
  • In many cases, the two systems work best together. ERP provides strategic oversight, while WMS delivers operational execution.

Why Choose a Best-of-Breed WMS

Many ERP vendors offer warehouse modules, but they often lack the depth of functionality required in complex distribution or manufacturing environments. A best-of-breed WMS, like the solutions provided by AscentWL, goes beyond basic inventory tracking. Our platform integrates seamlessly with ERP systems while delivering the real-time control and automation capabilities warehouses need to thrive.

With AscentWL, businesses gain:

  • Higher accuracy and throughput
  • Reduced labor costs and dwell time
  • Optimized use of space
  • Confidence to scale and expand operations

Ascent to Smarter Warehousing

ERPs and WMS platforms are not interchangeable. Each plays a distinct role in supporting modern supply chains. By understanding the difference, you can invest in the right system, or combination of systems, to improve both business visibility and warehouse execution.

At Ascent Warehouse Logistics, we design and implement warehouse automation software that delivers measurable results. From standalone WMS to integrated solutions with ERP, we help businesses achieve greater accuracy, productivity, and efficiency.
Is your warehouse ready to take the next step? Contact us today to explore how the right WMS can transform your operations.

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Tailored Solutions for Every Industry: From Aerospace to Pharma and Government

Tailored Solutions for Every Industry: From Aerospace to Pharma and Government

No two warehouses are the same—and that’s especially true across industries. A pharmaceutical distribution center has very different needs than an aerospace parts warehouse, a government logistics hub, or a manufacturing facility. At Ascent Warehouse Logistics (AscentWL), we understand that a one-size-fits-all approach simply doesn’t work.

That’s why we’ve built our integrated software and automation solutions to be modular, configurable, and scalable—so you get exactly what your operation demands, regardless of your industry.

Industry-Specific Challenges Require Industry-Specific Solutions

Each vertical market presents unique warehousing and fulfillment challenges:

Aerospace requires strict traceability, serialized inventory control, and uncompromising accuracy in storage and retrieval.

Manufacturing facilities demand work-in-process tracking, kitting, lot control, and seamless integration with ERP systems.

Pharmaceutical & Life Sciences distribution must meet rigorous regulatory requirements, ensure environmental monitoring, and support secure chain-of-custody processes.

Government & Defense operations often involve secure storage, classified materials management, and mission-critical logistics with zero tolerance for downtime.

3PL Providers must juggle multiple client inventories, dynamic order volumes, and rapid onboarding of new accounts.

AscentWL’s unified Supply Chain Execution (SCE) platform—encompassing WMS, WES, and WCS—empowers these industries to overcome their operational hurdles with precision and flexibility.

Aerospace: Built for Accuracy and Control

In aerospace warehousing, accuracy is non-negotiable. Whether it’s managing serialized parts, ensuring regulatory compliance, or supporting lean manufacturing strategies, our platform delivers the control and traceability needed for high-stakes operations.

Our WMS features:

  • Dynamic lot and serial number tracking
  • Advanced kitting workflows
  • Full integration with automated storage systems and carousels

Combined with automated picking systems and precise inventory control, we help aerospace clients streamline their operations while meeting strict industry standards.

Manufacturing: Supporting Lean & Just-in-Time Fulfillment

Manufacturers need warehouse solutions that go beyond finished goods handling. Our system enables visibility and control over:

  • Raw materials
  • Work-in-process (WIP) inventory
  • Cross-docking workflows
  • Custom kitting and staging

We integrate seamlessly with production schedules and ERP systems, allowing inventory to flow where and when it’s needed—helping manufacturers stay agile and efficient.

Pharma & Life Sciences: Secure, Compliant, and Controlled

Pharma and life sciences logistics face unique challenges in regulatory compliance and safety. AscentWL supports:

  • Full chain-of-custody tracking
  • Environmental monitoring and alerts (temperature, humidity, etc.)
  • Lot and expiration date control
  • Integration with quality management systems (QMS)

With these capabilities, pharmaceutical distributors can ensure patient safety while meeting FDA and global regulatory standards.

Government & Defense: Mission-Critical Logistics

Government and defense supply chains demand security, control, and uptime. AscentWL empowers these organizations with:

  • Controlled access and secure user authentication
  • Classified material handling support
  • Redundant system reliability for uninterrupted operations
  • Audit-ready reporting and compliance tracking

By combining operational expertise with automation, we help government entities achieve efficiency while maintaining strict oversight.

3PL: Flexibility for Multiple Clients and Workflows

Third-party logistics providers need a system that can manage diverse client requirements while maintaining efficiency and scalability. With AscentWL, 3PLs can:

  • Onboard new clients quickly
  • Configure client-specific rules for inventory, orders, and billing
  • Generate client-specific reporting and dashboards
  • Integrate with multiple upstream and downstream systems

We help 3PLs build competitive advantage through flexible, high-performing fulfillment.

Beyond Software: Operational and Automation Expertise

At AscentWL, we don’t just provide a software platform—we act as a strategic partner. Our Operational Services team works closely with clients to assess current processes and identify areas for improvement. These services include:

  • Warehouse layout and slotting design
  • Distribution center audits
  • Concepting and automation modeling
  • ROI and payback analysis

From day one, our goal is to help you maximize your facility’s potential—not just implement a system.

We also believe in empowering our clients through knowledge. Our Educational Series provides helpful insights into best practices, emerging technologies, and deep dives into WMS vs. ERP functionality, automation integration, and more.

Our relationship doesn’t end at go-live. We provide continuous support and evolve with your business as it grows.

Partner with a Team That Understands Your Industry

Whether you’re in aerospace, manufacturing, pharma, government, or 3PL, AscentWL delivers solutions tailored to your industry and your goals. With decades of operational expertise, advanced software, and integrated automation capabilities, we help warehouses operate smarter, faster, and more profitably.
 

Contact us today to schedule a warehouse assessment or explore how we can tailor a solution for your unique operational challenges.

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Maximizing Warehouse Performance with Integrated Automation & Software

Maximizing Warehouse Performance with Integrated Automation & Software

In today’s high-demand, fast-paced supply chain environment, warehouses face mounting pressure to deliver faster, more accurately, and with fewer resources. Rising labor costs, increasing customer expectations, and the complexity of multi-channel fulfillment make it clear: traditional warehouse operations are no longer enough.

To compete and scale effectively, businesses need more than just software or automation—they need a unified solution that brings both together. That’s where Ascent Warehouse Logistics delivers a powerful edge.

Unifying Software and Automation for End-to-End Performance

At AscentWL, we offer a fully integrated Supply Chain Execution (SCE) platform—built from the ground up to combine Warehouse Management Systems (WMS), Warehouse Execution Systems (WES), and Warehouse Control Systems (WCS) in a single, cohesive solution. This unified approach enables real-time visibility and control across every warehouse function: from receiving and putaway to picking, packing, shipping, and returns.

Our clients benefit from coordinated operations where software and automation are in constant sync. Whether you’re dealing with manual picking or high-speed automation, our platform adjusts dynamically—minimizing dwell time, reducing errors, and driving productivity.

Software Designed for Speed, Accuracy, and ROI

One of the greatest challenges in the marketplace is implementing warehouse software that adapts to real-world needs—without lengthy, costly customizations. At AscentWL, our software is modular, configurable, and highly scalable.

In fact, the majority of our implementations use standard product modules with minimal customization. This ensures fast deployment and rapid time-to-value, helping our clients go live faster—without compromising on performance.

Our platform supports:

  • Real-time RF communications
  • Advanced slot management
  • Hands-free voice-directed picking
  • Multi-zone replenishment and pick-to-light integration
  • Dynamic cartonization and kitting

The result? Warehouses operating with 99.5%+ inventory accuracy, improved throughput, better space utilization, and lower labor costs—across industries ranging from aerospace and manufacturing to e-commerce and 3PL.

Automation That Works—Because We Build It With You

Software alone isn’t enough. To fully optimize your facility, the systems must work hand-in-hand with the physical automation.

AscentWL is unique in the marketplace for delivering both the software and the automation hardware—and integrating them seamlessly. From robotic picking solutions and carousels to autonomous mobile robots (AMRs) and advanced conveyor systems, our team designs and delivers solutions that match your facility’s workflow, layout, and growth plans.

We don’t just bolt on third-party equipment—we ensure every piece of automation is purpose-fit and coordinated through our unified platform.

Real Results from Real Operations

Our clients consistently report measurable improvements across key performance indicators. One customer in the e-commerce space saw a 60% increase in order volume, while reducing staff by 20%, thanks to our integrated software and automation approach.

Another facility cut its average pick time in half and increased dock-to-stock cycle efficiency by over 35%. These aren’t outliers—they’re the result of a repeatable, proven process that AscentWL has implemented across hundreds of facilities nationwide.

A Consultative Approach from Start to Finish

We don’t believe in cookie-cutter deployments. Every engagement starts with a deep operational assessment—from layout design and slotting strategy to throughput modeling and growth planning.

Whether you’re retrofitting a legacy facility or building a new DC from scratch, we bring both strategic insight and hands-on execution. Our team includes not just software developers and automation engineers, but also operational experts with decades of warehouse management experience.

Ready to Optimize Your Warehouse?

If you’re ready to reduce operating costs, improve accuracy, and increase throughput—let’s talk. At Ascent Warehouse Logistics, we help clients move beyond the status quo with solutions built for long-term success.

📞 Schedule a Warehouse Review
 📨 Or contact our team to learn more about how AscentWL can transform your operations.

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Join us at Modex 2024!

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Join us at Modex 2024!

March 11th-14th, 2024,

Georgia World Congress Center, Atlanta, GA. 

Come see us at booth B5011. We’d love to talk with you about warehouse productivity, operational performance and accuracy, lowering labor costs, and more.

Schedule a Meeting

Ready to see how Ascent’s warehouse automation software can help you improve efficiency and attain operational accuracies of 99.5% or better? Contact us now!

About Ascent Warehouse Logistics

Ascent Warehouse Logistics creates and implements automated warehouse solutions. Ascent upgrades warehouse performance by reviewing current baselines, identifying and quantifying areas of concern, and proposing cost effective solutions. By leveraging the expertise of both Intek and Minerva Associates, Ascent Warehouse Logistics delivers comprehensive software and hardware material handling solutions and automation.

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Increasing Supply Chain Agility With WMS -A Guide for the C Suite

Increasing Supply Chain Agility with WMS: A Guide for the C-Suite

In today’s fast-paced business world, supply chain agility and resilience have become more important than ever. To stay competitive, businesses need to optimize their operations and minimize costs, while also ensuring their customers receive the best possible service. Warehouse Management Systems (WMS) have emerged as a key tool for achieving these goals. By automating and streamlining warehouse processes, WMS solutions can increase efficiency, accuracy, and visibility across the supply chain.

But how do you convince the C-suite to invest in a WMS solution? That’s where our latest episode of the MHI Industry Leadership Podcast comes in. Our guests, Phil Hawbaker and Stan McLean from the MHI Solutions Community, share their insights on how to make a compelling business case for WMS to the C-suite. They discuss the benefits of implementing a WMS, including increased efficiency and accuracy, and offer strategies for calculating ROI and demonstrating the long-term value of a WMS investment.

Whether you’re a business owner, a supply chain professional, or simply curious about the latest trends and innovations in the industry, this episode is a must-listen. Tune in to the MHI Industry Leadership Podcast and learn how WMS solutions can help your organization thrive in today’s dynamic business environment.


Listen Here

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Warehouse Management System

Warehouse Integration and Automation Decisions

Warehouse Integration and Automation Decisions

Those tasked with preparing for the future of automation don’t have an easy path in front of them. Nevertheless, the innovation that developing robotic machines produce can be exciting. There are opportunities to grow and streamline many types of businesses. With streamlined control, disparate software challenges and maintenance hassles can fade away.

Selecting Vendors

One of the best decisions a material environment can make is choosing vendors with the proper knowledge and perspective. In selecting vendors, it is important to try to choose ones who have a proactive, big-picture view. The temptation is to choose vendors whose expertise is deep in one area. Expertise about one piece of machinery, or a line of machines, can feel extremely valuable. However, this is often a short-term solution that provides limited long-term value. Expertise with the controls of only one line of machines fails to assist much in a long-term strategy.

Vendors with Long-Term Foresight

Failing to choose vendors who hold an eagle-eye view of logistics, warehouses, and the drift toward automation and robotics has consequences. Without foresight, a COO can end up trying to reassess and renovate their software and machinery situation every few years. Expanding possibilities for robotic integration should be the priority.

Having a ten or fifteen-year perspective and level of proactivity saves effort. A long-term decision is to value and implement an agnostic software solution. A comprehensive WCS can ensure a business is not limited by past investments to old machinery and the associated software. Old software that is unlinked will hold back the possibilities for streamlining and automation. Warehouse operations, distribution centers, and large corporations with warehouses that plan for the future will reap the benefits.

Selecting Groups Who Understand Business Strategy and Technology

In business, having great vision and a clear direction are invaluable skills. Warehousing and logistics are no different. On a large and small scale, focusing on growth and optimization is invaluable. When each item, package, or pallet flows toward its ultimate destination sooner, the streams of small actions add up.

To help create a current of efficiency, vendors who speak the languages of logistics, technology and business make the best partners. When a vendor understands overall operations, the need to constantly explain dissipates. Operators won’t need to brainstorm workarounds resulting from vendors’ lack of understanding. Cobbling together solutions isn’t necessary. Solutions providers who think long-term and are already acquainted with your pain points help operators develop and execute a strategy for proactive, long-term success with fewer adjustments.

Selecting Appropriate Machinery

Choose machinery with the future in mind. For each specific task, the appropriate, best-fit machine makes a world of difference. If an AS/RS serves the objectives better, settling for three carousels is not worthwhile. Creating a future-focused plan hospitable to robotics, and prioritizing machinery that fits within that plan, can pay off.

The Utility of Robotics

One area where robotic solutions are advancing rapidly is for clearly defined tasks. Having robots complete simple, discrete tasks can be wise. The machines ceding tasks to robotic machines at present are conveyors. While conveyors bolted to the floor provide limited movement of goods, agile robots will prove useful for movement-based tasks. It is easy to imagine that by using sensors, they become capable of more efficient movement. By multiplying this agility beyond the limited movement of conveyors, much more efficiency becomes possible.

Robotics OEM Software

Robotics machines are usually packaged with OEM software. This OEM-supply WCS is limited in many cases. Integrating them into a broad software solution in warehouses on a wider scale can be challenging, yet may produce  quality results.

AMR Robots

Autonomous mobile robots (AMRs) used for transportation have proven to be a great addition to an overall solution for warehouses. They can work with automated storage devices. However, they’re not capable of interfacing to the certain carousels. Two separate WCSs create unneeded steps and clutter in terms of the volume of software needed. The need to manage and maintain that software piles on extra layers of complexity.

The Evolution of Robotics and WCS

As robotics progress beyond AMRs to those capable of more complex tasks, using one comprehensive warehouse control system software will become increasingly important. Presently, robots completing discrete actions or traveling between points don’t need to communicate with other machines often. As the possibilities for robotics develop, an OEM WCS’s limits would become apparent. For example, the possibility of gamifying the warehouse with augmented reality could make warehouse operations more efficient. The control system from a robotics or carousel manufacturer can’t be expected to control the interface to the user. An agnostic, high-level WCS would shine in managing more developed robotics, along with more classic machines like carousels.

OEM WCS Database Concerns

The prohibitive nature of OEM warehouse control systems not having a robust database is a concern. That is especially the case when trying to plan a road map for warehousing or distribution. Typically, the limited database of OEM software will slow down the progression toward the business’s goals in the future. Avoiding decisions or maintenance of systems that will not scale with discrete should be a priority. In fact, by not controlling the machines from a high, informed level and letting them work together, the business is not maximizing its investment in the machines. Nor is software providing a good return on the investment. By controlling through a higher level, more informed warehouse control system software, unprecedented cohesion becomes possible.

A Proactive Modular WCS Software Roadmap

Taking a bird’s eye, long-term view for ten years is key to making the correct decisions for warehouse control system software. Synchronizing the road map between vendors and other partners will help the business advance toward its goals. Crafting an automation roadmap with scalable software that is financially modular is the best option. A comprehensive WCS designed to be modular and priced according to the currently needed modules can make the difference. As needs change, scaling up within the next month should be possible. Growing with modules of software is easier than adapting to new software packages.

Warehouse Control System Software for the Future

The future of robotic integration into the material-handling world is exciting. With foresight and a well-formulated strategy for software and machinery cohesion, efficiency can soar. High-level warehouse control system software can propel businesses further. Businesses relying on many separate WCSs that came with the machinery will need to keep maintaining them. They’ll need to keep dealing with their limitations and the inefficiency of a disjointed web of disparate software. Meanwhile, those using a streamlined WCS solution will do more with less software. They can push warehouse operations further, faster.

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Warehouse Management System

Programmable Logic Controller (PLC) vs Warehouse Control System (WCS)

Programmable Logic Controller (PLC) vs Warehouse Control System (WCS)

Some of the abilities of a programmable logic controller are similar to those of a warehouse control system software. However, they are too limited in volume of commands. Lacking a database, a PLC can only be directed for a limited number of actions. Meanwhile, a centralized WCS can feed information to devices more slowly, on a time-dependent basis. A PLC cannot meter commands like a WCS. It cannot store many commands because the database is too small.

A centralized WCS has more human-like intelligence that can orchestrate different machines simultaneously throughout a daily cycle by gathering and metering more real-time information. A WCS has this capacity due to its database size.

Combining WMS, WES and WCS

With a centralized, agnostic warehouse control system software, the need for separate WMS and WES lessens. Warehouse stock control software can be an involved task to implement. The best solution is a comprehensive package. A business can buy a package performing all three functions. Better yet, it can be a modular package. Components could be added as new needs arise. A modular WCS would be suited to the diverse needs of a distribution environment, a manufacturing environment or a corporation’s warehouse. Beyond being adaptable to the type of center, a modular WCS can scale as the business develops.

With modular options, the software expenditure can become commensurate with business needs. Why should a company pay for a comprehensive software solution when it only uses 70% of it? That vendor is over-solving their client’s software problems and needs. In effect, they are charging for unused functionality.

New ERP or ERP Expansion Considerations

When weighing options for improving control and leverage over automated equipment, many people consider ERP-based options. They think the best route would be to start moving into unused portions of their existing ERP. Many operators believe their existing ERP has additional functionality for automation that could be useful or consider upgrading it. However, an ERP is often lacking in quality warehouse control system software.

A simple WCS connected to an ERP may produce narrow results. When a WMS  is involved with the ERP, the information delivered is broader. It’s not limited by what is stored in that device.

Warehouse Control System Software Data Flow

The flow of data and commands between warehouse control system software to different locations varies depending on the type of connection. When it flows down to a device, time is a priority. Meanwhile, when interfacing to an ERP, time is not of the essence.

Data Between a WCS and a Device

An advantage of warehouse control system software sending a command to a device is that a response can return immediately. The device can quickly affirm when it will complete the task. This can happen on the scale of a millisecond. It happens in real time, using a web service, a web API or a TCP/IP interface. Faster response times keep many types of actions moving forward in a distribution center or warehouse. Databases don’t allow for a real-time interface.

Data Between a WCS and an ERP

When interfacing to an ERP, real-time interactions are not a priority. An ERP system doesn’t care when the designated action occurs. It could take place in the next 30 seconds or five minutes later. When a WCS interfaces to a device, time is a priority. The result is that a WCS provides the level of necessary responsiveness. An ERP isn’t as sensitive to time.

Cloud or Local Warehouse Control System Software

It’s important to consider whether warehouse control system software or its components should reside in the cloud. Guaranteeing responsiveness is a vital part of location considerations. Those with experience in WCS operations warn of the challenges of securing real-time interface to that piece of machinery. There are instances when dark fiber can guarantee a high level of response. In that case, a WCS that resides in the cloud can work well. However, guaranteeing real-time response with cloud-hosted databases remains a major challenge for a lot of companies.

In many cases, some components end up being housed in the cloud, while others remain local. This hybrid situation can keep operations running smoothly. Components that do not depend on a sensitive, millisecond response time can be stored in the cloud. Meanwhile, on-premises machinery interfaces can better guarantee the faster travel of information. Speed is the key.

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Warehouse Management System

Robotics and Warehouse Control System Software

Robotics and Warehouse Control System Software

Warehouse control system software can automate and command devices and machinery in innovative ways. As robotics advance, moving toward a more cohesive control structure can yield streamlined, efficient results. Machines controlled by a comprehensive (WCS) warehouse control system include storage devices like an automated storage and retrieval system. Vertical lift modules and similar machines could also be operated by a WCS. Many other devices in warehouse and distribution center environments can be automated and optimized by warehouse control system software.

A comprehensive WCS can not only control the machines’ function but operate in real time. The real-time capacity of broad warehouse control systems offers more sensitivity to current warehouse needs. With real-time information, each decision can be made from a more informed standpoint. The result for a warehouse with WCS is better, faster decisions. The ultimate outcome of more informed commands and actions is getting material where it needs to go faster.

Automated Equipment Software

A comprehensive WCS, (warehouse control system) can interface with many types of machinery. These include vertical or horizontal carousels. It also interfaces with conveyor systems and sortation systems. Pick-to-light and put-to-light systems that give order pickers clear instructions can also be controlled by a WCS. As automation and robotics evolve, a high-level WCS can reduce disjointed situations in warehouses. Many types of machines, including robotic ones, can be controlled to work in harmony.

Warehouse Control System (WCS)

A machine in a warehouse needs commands to operate. Of course, in the past, a human would direct the machine. Control through a WCS provides an opportunity to remove human labor resources. This solution can combat labor shortages and scheduling difficulties. A WCS can manage and automate the activities of a machine. The person or the few people controlling a broad WCS have more leverage over the machines operating in a warehouse or distribution center.

WMS and ERP Software Interface

A WCS can talk to other business systems. Enterprise research planning (ERP) software like Oracle can interface with it. A WCS can communicate with a warehouse management system (WMS) that helps with the flow of inventory and goods. Typically, it lives in the middle of the architecture. It communicates at different speeds to different partner software and controls like warehouse inventory control system software.

Warehouse Control System Software Database Advantages

One advantage of comprehensive warehouse control software is the options provided by the database. Machine controls can’t usually handle large databases. A WCS offers the functionality to connect with a database. It can also integrate data from an ERP system and parses the data into simpler commands the controls can digest.

From the central location in the architecture, the WCS controls the equipment. Since it can process real-time data, its commands flow from the warehouse’s overall needs at that moment. The tasks are carried out by the machines within an optimized timeframe and with optimized speed. The reduced interval of time from task creation to successful task completion is crucial. Real-time data and faster execution make a big difference.

OEM WCS Automation

Automation equipment is frequently packaged with a warehouse control system. Although the equipment has controls, they are situated at too low of a level. They only operate that individual machine. For example, a vertical lift module’s WCS may not talk to a carousel’s WCS. Warehouse operators are not getting much more leverage over the machines. A centralized WCS can optimize, connect, and process more systems. It is agnostic, meaning it can control many different machines.

A WCS can sometimes integrate to an ERP. However, in most cases, there are massive differences in coding structures. Integration isn’t practical, and it’s not often worth the effort of integration.

OEM WCS Isolation

The scope of warehouse control system software applications can vary widely. Some arrive with and solely work with the machinery, while others can control any type of machinery. A vertical lift module with a WCS from a manufacturer cannot communicate with a vertical carousel’s distinct WCS. The result is two islands of non-communicative software. A high-level WCS could control both. It synthesizes operations in a warehouse or distribution center.

When improved streamlining and coordination is feasible, it provides a higher return on investment. It’s more feasible to benefit from investments in machinery, software and personnel. The expertise of operators stays shallower when there are many software packages. Employees working in fewer warehouse control systems have more time and incentive to learn and remember details and quirks.

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Warehouse Management System

The Key Factors to Consider Before Implementing Robots in Your Warehouse

The Key Factors to Consider Before Implementing Robots in Your Warehouse

Warehouse robots are increasingly essential in retail, distribution, and manufacturing environments. For years now, robots have been used for single, discreet warehouse tasks. Today, however, robots are being implemented for more and more complex warehouse operations. This increased demand is being driven by multiple factors, including accelerating e-commerce growth, pressure from consumers for faster turnaround on orders, and growing competition for labor.  

Could warehouse robots improve your operations and overall performance? Do you know which warehouse automation solutions are optimal for your business?

Here are the key factors to consider before adding robots to your warehouse:

Warehouse robots come in a variety of types, with different capabilities and features

When it comes to warehouse control systems, robots are just another form of automation. That means you are likely already familiar with some types of warehouse robots, while others may be completely new to you. It is important to understand how warehouse automation has evolved and the wide array of features and capabilities now available.

 Types of warehouse automation

  • Goods-to-person (GTP) solutions utilize an operator based in a centralized location, and the goods move to the operator, rather than the operator moving to the goods. The term “goods-to-person” applies whether the goods are moved by an autonomous robot or some other form of warehouse automation such as a vertical or horizontal carousel or a vertical lift module (VLM). With a true goods-to-person solution, the product picked is a single item or handful of items from a larger inventory stored within that automated media.
  • Shuttle systems deliver product without using an operator. For example, a shuttle system or a rail crane can pick up full pallets of product from a high-density pallet storage solution. The product is retrieved and then staged or conveyed through a conveyor system for delivery to the next part of the process such as pick-to-light or a put-wall that is downstream of the storage solution.

Both GTP and shuttle systems can involve machine learning and artificial intelligence (AI) capabilities. This technology now ranges from simple software and autonomous functionality to much more advanced systems with complex sensors and sophisticated predictive analytics.

For example, autonomous mobile robots (AMRs) are gaining traction across a range of distribution environments. Simple AMRs can be programmed and implemented quickly, without a lot of overhead, to accomplish repetitive tasks, such as moving product from one location to another.

Articulating pick robots are also becoming more popular. These robots have the intelligence to discern among mixed products in a single bin, cart, or tote. An articulating pick robot is smart enough to recognize a wanted item, find it, and then move its arm to pick the item. Some can even distinguish damaged items and reject them. When equipped with machine learning, these robots learn about the product base and how best to fulfill orders, and they improve over time.  

Understanding the scope of features and capabilities currently available can help you find the warehouse automation solution that will be most useful in your warehouse.

Determining the “why” is critical

 It is crucial to identify the specific role robots will play in improving the operation of your facility. Generally speaking, the top reasons companies opt for warehouse automation are to:

  • Optimize the footprint of a warehouse facility. Storing and moving items more efficiently makes the most of existing space.
  • Improve pick rates without additional labor. The right solution enhances the performance of the current workforce.
  • Improve the customer experience. Increasing pick rate and accuracy means customers get their orders fulfilled faster and without error.
  • Modernize and automate. Eventually, legacy warehouse systems need to be replaced, especially when maintenance and repair budgets become excessive.

Calculating the ROI of warehouse robots

While evaluating options, be sure to calculate the return on investment (ROI) of different warehouse automation types. First, identify warehouse operations that involve demonstrable, repetitive tasks and determine the hard costs associated them. Then, compare that to the cost of buying or leasing a robot that could assume those responsibilities.

For instance, simple time-and-motion studies of warehouse associates have found 60% of their time is spent walking. Buying or leasing AMRs or other type of warehouse robot can dramatically reduce or eliminate that walking time and result in significant labor cost savings. Warehouse robots can also help businesses adjust to peak season surges and dips.

Robots must be integrated with warehouse processes

To be effective, warehouse robots must be integrated with other warehouse processes. Remember: Warehouse automation is not meant to function as standalone technology. Instead, it needs to be connected to other automation and warehouse processes.

Working with an experienced warehouse automation provider will help you avoid creating islands of robot technology. That’s why it is so important to look for a warehouse robot vendor that can combine warehouse management (WMS), warehouse execution (WES), and warehouse control systems (WCS) into a single package.

 The goal is to improve warehouse productivity using technologies that can blend with your current warehouse operations. Ultimately, that solution could involve AMRs, an automated storage conveyance system, pick by light, or another type of warehouse robot. The right vendor will deliver a complete solution that seamlessly integrates today’s automation technology to optimize results.