Self-optimising technologies from Pennsylvania-based Lucas Systems use digital-twin mapping to help warehouses adjust in real time.

The software enhancements can help warehouses make quicker and more effective decisions related to order batching and prioritisation, warehouse worker travel, and slotting.

With the addition of algorithms and digital twin mapping of the warehouse, Lucas Systems’ DWO dynamic work optimisation (www.lucasware.com/travel-optimization) delivers more effective warehouse performance by considering in-the-moment complexities related to order priority, SKU clustering, proximity and warehouse layout.

Additionally, the enhanced software promises a reduction of up to 50% in the number of steps workers take inside the warehouse by optimising pick paths in a way that considers the least amount of travel time required. Pick path recommendations now factor in the effect of forklifts and cherry pickers, and Lucas says these details matter.

In recent months, Lucas executives have announced dynamically-driven technologies to help warehouse operators quickly adapt to changing operational conditions or shifts in demand. Dynamic slotting (www.lucasware.com/new-ai-powered-dynamic-slotting-simplifies-warehouse-reslotting-with-click-of-a-button) technologies are an example. Announced earlier this year, their benefit is to simplify re-slotting by providing in-the-moment recommendations, powered by AI. They apply machine-learning algorithms to recommend which products should be moved. They also learn the spatial characteristics of a warehouse and predict task time based on activity-level data. The model then continues to learn, providing continuous optimisation as conditions change.

Lucas says warehouse agility is key to a company’s future growth and is necessary in these times. It has outlined its vision for creating a dynamically-driven warehouses in a report, The Transformational Promise of the Dynamic Warehouse (www.lucasware.com/the-dynamic-warehouse). The report includes customer insights and strategies and considerations for change.

“You cannot future proof your warehouse with fixed or mechanical automation,” said Ken Ramoutar, CMO of Lucas Systems (www.lucasware.com). “Rising supply chain volatility requires adaptive operations with in-the-moment smart decision support. The more agile your operations are, the more you’ll be able to capitalise on opportunities and minimise the impact of disruptions and then course correct them.”

Ramoutar described a dynamic warehouse as having the smart software and decision-making technology to:

• Be self-optimising – make real-time optimised decisions on work execution, priorities and labour assignments
• Enable managers to implement change quickly upon learning new insights
• Efficiently optimise the use of warehouse resources, including the workforce
• Allow automation such as robotics to be introduced and orchestrated seamlessly
• Cost-efficiently adapt to changes in demand profiles, supply disruption and resource availability

“The agility from smart software will help warehouses respond cost effectively to supply chain disruptions and other fluctuating market dynamics,” said Ramoutar. “Warehouses that aren’t dynamic will face significant long-term challenges with warehouse performance and more demanding customer service levels.”