The intelligent warehouse transformation was based on an existing old warehouse, presenting several challenges:

 Limitation of Original Flat Warehouse Management on Production Capacity

On one hand, the original warehouse had a long distance to the production line, complicated working conditions, and difficulties in manual operation. On the other hand, the old warehouse had complex ground conditions, with underground channels affecting the layout of intelligent storage equipment.

High Error Rate in Manual Warehouse In-and-Out Operations

During routine product receiving, storage, and dispatch, issues like miscalculation, inspection negligence, poor management, natural wastage, and accounting errors led to surplus, shortage, and damage of goods, resulting in discrepancies between inventory records and actual stock.

Excessive and Insufficient Inventory Leading to Low Storage Efficiency and Management Challenges

In response to these pain points, Zikoo Robotics designed a five-level pallet shuttle car high-density storage solution for the enterprise. The warehouse, covering 1750 square meters with a height of 15 meters, includes 3360 storage positions. The system comprises multi-directional shuttle cars, stacking AGVs, high-speed elevators, flexible conveyance lines, and an intelligent storage software system (including WMS and WCS), and accompanying information systems, achieving fully automated storage management. Pallets carrying products are automated for both storage and retrieval, seamlessly integrating with external forklift AGVs and various production lines for a fully automated and unmanned operation, effectively addressing the enterprise’s multiple pain points. The system also allows for future expansion of racks and conveyance equipment to further enhance retrieval efficiency and production capacity.

The multi-directional shuttle cars can move freely in all directions within the high-density racks, achieving storage and retrieval in any position within the three-dimensional space. Meanwhile, the warehouse’s in-and-out points correspond to the multi-level production lines of the injection molding factory, shortening the distance between the production line and the warehouse, saving storage space, and increasing the overall space utilization of the warehouse. This results in increased production capacity, with storage capacity enhanced to 5-6 times that of the original warehouse. The adaptability of the shuttle cars to irregular spaces was a significant advantage during the old warehouse renovation, improving operational efficiency by 20% and reducing energy consumption by 30%.

Zikoo Robotics’ in-house intelligent storage software system was directly integrated with the client’s ERP system. Using PDAs to scan documents, it manages in-house tasks like storage, retrieval, and allocation. Additionally, the system was customized for the specific needs of the Cixi warehouse, addressing distinct storage area requirements for different materials and intelligently handling specific storage allocation strategies.

To address issues of excess and insufficient inventory in the old warehouse, the automated system includes order management for warehouse entries and exits, inventory management, stocktaking, warehouse space visualization, and charging strategies for carts. For instance, the inventory management’s alert feature accurately tracks product inventory, enabling real-time confirmation of minimum, maximum, and safety stock levels, thereby facilitating timely alerts for inventory adjustment, production capacity changes, and purchasing.

The unloading of materials from the high-density warehouse doesn’t require manual operation at the exit. The system automatically assigns transport tasks to AGVs, transporting pallets to designated locations, thereby realizing an automated “goods-to-person” process, reducing manual labor and associated risks.

Zikoo Robotics’ solution for the injection molding manufacturing enterprise boasts high efficiency, density, flexibility, low cost, and increased intelligence. It assists the enterprise in transitioning from traditional to automated warehousing, maximizing investment returns, and significantly enhancing the company’s core competitive edge.