Automated systems have the potential to significantly improve the efficiencies of distribution centers. And that's exactly what one plastics manufacturer discovered when it replaced a manual lift truck fleet with a fleet that includes automated lift trucks and automatic guided vehicles (AGVs). Throughput in this Midwest warehouse has doubled since replacement of its manual truck fleet.

The company was considering an automated storage and retrieval system that would speed operations and increase capacity. After review, however, it decided that a fleet of automated very narrow aisle (VNA) trucks and fork-style AGVs would be most beneficial.

The results were immediate. In addition to higher throughput, the switch to VNA trucks allowed the warehouse to reduce the space between its aisles from 12 feet to less than 6 feet. The trucks only need 68 inches to operate. The new space for additional racking has resulted in an increase of 380% more storage space in the warehouse.

The system's traffic routing AGV command executive (TRACE) operating software, a Windows-NT compatible program, controls the entire operation. TRACE synchronizes material movement with product demand, generates new orders and pickup/drop-off locations and communicates with existing warehouse systems. The trucks have on-board software controlled by TRACE, allowing them to determine the closest available storage location and "remember" it for future retrieval.

Workers manually palletize finished goods from the assembly line before they are labeled and wrapped. Throughout this process, sensors monitor the load's physical size and communicate it to TRACE. Trucks then use this information to store the load in a storage space that most closely matches its size.

The system also accommodates kitted pallets, or pallets that require configuration with assorted product before they are sent out. When a kitted order enters the system, TRACE notifies the automated trucks, which bring full pallets to a special station. There, new pallets are manually consolidated according to specific orders. Once product is taken from the original pallets, the remaining pallets are transported to conveyors where they are re-wrapped and fitted with newly generated bar code labels. These pallets are then automatically re-warehoused, while the new kitted pallets are delivered to the shipping area by the automated truck fleet.

Users can also easily change the paths the trucks follow. Point-and-click software allows users to visually map out guidepath routes for the trucks.

In addition, the plastics manufacturer has seen multiple benefits from the automated trucks, with reduced cost for lift truck maintenance and the cost of the staff to maintain them. The products have seen less damage and spend less time traveling throughout the warehouse.