Hypermarket Warehouse Automation
Smart warehouse automation system for an omnichannel retail business
- AI
- Retail
- Supply chain
- Transformation
- Automation
About the client
Our client is one of the largest hypermarket chains in their country. They aim to strengthen their online presence by offering their customers an omnichannel platform where they can order groceries and receive them within 1-2 hours.Details
- Date:2022
PixelPlex helped its client conduct comprehensive research into automating their warehouse and improving the speed and efficiency of product delivery by implementing intelligent storage solutions, robotic lifts, and automated conveyor systems.
Team
- Project manager
- Business analyst
- Full-stack developer
- Data scientist
- Hardware engineer
Project goals
- 1
Implement a fully-automated smart warehouse system to speed up product delivery
- 2
Develop a visualization prototype using digital twin technology to demonstrate system functionality
- 3
Prepare comprehensive technical documentation for the future system
- 4
Ensure efficient order collection with no congestion
- 5
Provide a solution for how equipment can deliver items to the cashier intact and undamaged
Work done
- Developed a comprehensive vision for a smart warehouse automation system
- Created a visualization prototype showing how the system works non-stop
- Consulted with suppliers to select the most suitable equipment
- Prepared detailed technical specifications for vendors to develop and manufacture a custom warehouse automation system
- Completed project preparation up until the equipment purchasing stage
Business opportunity
With the rise of online grocery delivery, our client recognized the need to optimize their order fulfillment process and last-mile delivery solutions.This decision was motivated by their outdated and inefficient method of order collection, which relied on staff members who physically searched the supermarket for specific items. This led to unnecessary delays because sometimes products were unavailable and staff needed to contact the customer and change the order.To address these issues and ensure a seamless and efficient delivery experience for their customers, our client needed to re-imagine and improve their processes.
Solution
We proposed the idea of an innovative warehouse equipped with intelligent storage solutions, robotic lifts, and automated conveyor belts to streamline the order fulfillment and delivery process, reduce human intervention, and boost overall efficiency.The system alerts administrators when goods are about to run out, minimizing the risk of items becoming unavailable.
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Details
Smart delivery system: hardware
- 20 robotic liftsfor delivering goods carefully from intelligent storage solutions to automated conveyor belts
- 50 intelligent storage solutionsfor storing and organizing items by type, size, weight, and material
- 300-meter-long automated conveyor belt systemfor transporting goods from storage to the cashier
Workforce optimization in the delivery process
- Vending machine stockerMonitors the loading of storage solutions, replenishing items when necessary
- CashierReceives boxes with goods, packs items for delivery and hands them over to the courier
- CourierPicks up orders from the cashier and delivers them to customers
Manual labor vs. the automated system
- By80%Reduced the time required for order collection
- By58%Labor costs decreased due to the reduced need for manual order pickers
- By95%Reduced the number of human errors in the order collection process
AI-powered order picking: the flow
Our team proposed the following flow to automate the order fulfillment process:
- 1
The system receives an order through API.
- 2
Intelligent storage solutions receive a signal and prepare items for withdrawal.
- 3
Robotic lifts pick up items and place them in boxes on conveyor belts.
- 4
The boxed orders are transported to the checkout.
- 5
The cashier packs the items into shopping bags and updates the status for pickup.
- 6
The courier receives the order for delivery.
- 25min → 7 minReduction in average time for order collection
- 24/7Non-stop operational capacity of the warehouse automation system
Visualization model
We ensured smooth system functioning, preventing congestion on the conveyor belts by thoroughly planning the logistical route of orders within the warehouse.
PixelPlex developers made detailed calculations of how products would move along the system and how manual labor would be allocated. They then created a precise and detailed visualization of the process.
The model demonstrated a 10-minute average order collection time, with the system operating non-stop.
Software integrations
We provided our client with expert advice on the software and integrations needed for seamless warehouse operations and delivery systems.
We recommended developing custom software for hardware management, including an admin panel. Administrators would be able to monitor the state of the equipment and receive timely notifications for restocking.The application would replace the software previously used by manual order pickers, as the new system eliminates this role.
Project features
Innovative approach to omnichannel order fulfillment
Smart system with optimized logistics routes from intelligent storage solutions to couriers
Detailed vision of non-stop warehouse operations
Prevention of congestion on conveyor belts
Reduced manual labor, leading to less human error and fewer delivery delays
Increased efficiency of the order collection process
Accelerated delivery times
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