Benefits of Dock Automation

Dock automation is the concept of improving the loading and unloading process at your shipping and receiving docks through the use of various material handling equipment and technologies. With dock automation, you can speed up the loading and unloading and get more product through the supply chain while reducing costs. Docking processes can either be semi- or fully-automated, depending on the extent of the systems and equipment used.


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In general, automated docking has two phases which determine the full scale of automation:

  1. In-trailer automation: Warehouses can automate the process of loading and unloading goods to or from the trailer itself. Material handling equipment and conveyors can automatically load or unload pallets and boxes. When loading, the conveyors neatly and safely stack the pallets and boxes. When unloading, the automated technology will unload boxes and pallets in a controlled and safe way.
  2. In-warehouse automation: When receiving goods, and once the pallets have been automatically removed from the trailer, automatic processes will move the goods from the trailer to the dock, where they can be sorted into production areas. When shipping goods, dock automation equipment gathers pallets or boxes from the production areas to get them ready for automated loading into the truck.

While most people think of robotic conveyor technology when discussing dock automation, there are other types of material handling and warehouse equipment that can automate the loading and unloading processes. Skates, rollers and forklifts all have a role to play in automating the docking process, while pallet dispensers, changers and wrapping machines also help streamline the process either semi- or fully automatically. To better understand how critical warehouse automation is to business performance, let’s explore these nine benefits of dock automation.

Dock Automation Benefits

1. Improves Dock Safety

When considering investing in dock automation technology and equipment, it’s important to think of the long-term payoff. Automation may be a large upfront cost, but it will ultimately earn a return on investment by reducing both the immediate and long-term costs of operating. One of the most critical areas of long-term savings you earn from dock automation is through improved workplace safety

According to the Occupational Safety and Health Administration (OSHA), dock safety is one of the most important areas of concern facing warehouse employees. Loading docks are busy, active zones with large moving equipment and heavy loads. The more product being moved, the more equipment is required to run an efficient operation. OSHA warns that forklifts present the most significant risk of hazards. Incidents can occur when forklifts run off the edge of the dock due to be improperly operated. When forklifts aren’t loaded to an even and balanced weight, pallets or boxes can fall on workers during loading and unloading. At the dock, there’s also a risk of equipment striking a worker when not being operated properly and attentively often because there isn’t enough pedestrian space. One of the most tragic incidents that can occur is when a worker becomes pinned between the dock and the truck, trapping them there potentially unnoticed.

Forklift Operation in the Dock Area

The most important benefit of automatic loading is the reduced number of workplace incidents and the lowered risk of injury. Without automation, multiple workers drive multiple forklifts in the same centralized area, naturally increasing the risk of incidents. Loading dock automation effectively eliminates this congestion by requiring fewer forklifts and fewer workers gathered in one area. Because workplace incidents can be costly as well as tragic, warehouses can keep their staff safe and preserve their bottom line with automatic loading systems. Warehouse automation, in general, promotes a much safer working environment.

2. Reduces Energy Costs

In cold storage and frozen food warehouses, one of the most pressing issues facing supply chain managers is the rising cost of energy. Cold storage requires a considerable amount of energy to operate, accounting for a significant portion of the business’s overall operating expenses. Climate-control requires 24/7 monitoring, and it’s much more expensive to keep a facility cool than it is to preserve heat.

Cold air loss can happen when goods get retrieved during the loading process. Every time a door is opened or a curtain is pulled back to access cold storage, there’s an automatic loss of cold as outside warmer air seeps in. Because cold storage and frozen food goods are so sensitive to climate and require a set temperature to prevent spoilage, maintaining appropriate levels of cold is paramount to successful business. To ensure that cold storage warehouses maintain cool temperatures and maximize energy consumption, managers are wise to look at how warehouse automation solutions, such as automatic loading, can solve this major concern.

Reduce Energy Costs in the Dock Area

Automatic pallet retrieval systems for cold storage facilities streamline the loading and unloading processes through automation, and they also address energy efficiency concerns. Pallet retrievers automate the movement of pallets in and out of a climate-controlled zone through smaller openings. With high-speed doors that quickly seal, you can easily and seamlessly retrieve pallets with much less cold air loss. You’ll automatically keep more cold air inside the controlled zone and prevent condensation from building up. Your business will cut energy costs because the cooling system won’t have to kick-in in response to warm air, meaning it operates more efficiently.

3. Reduces Wear on Equipment

With the conventional loading and unloading process, warehouses require numerous forklifts. Multiple forklift trips are coordinated and timed to run back and forth between the truck, the loading dock, the production areas and the inventory storage destinations. Warehouse work is not delicate, and the rugged environment and consistent operation can quickly run down expensive equipment.

The costs of ongoing maintenance of multiple forklifts can add up. It may require a full-time staff of mechanics or hiring technicians and paying a premium to have them available for immediate repairs. Over time, these maintenance costs accumulate in several ways. The more wear and tear a forklift undergoes, the more it depreciates and the less value your fleet will retain. Don’t forget that forklifts are operated by humans, and humans make mistakes. They can have accidents or misuse forklifts, leading to expensive damage or write-offs. Additionally, when forklifts encounter unexpected downtime due to a breakdown, it can also stall up the loading and unloading process, incurring more labor costs by reducing productivity.

Cost of Ongoing Forklift Maintenance and Repair

With an automated loading dock, your forklifts won’t be used as frequently, meaning there will be less wear and tear. With less wear and tear, you can save your budget allocated for servicing and preventive maintenance and put it towards reinvestment in business operations, like automated technology. Automated systems require far less maintenance than mechanical equipment does. That’s because automation, by its very nature, is a smooth and consistent process. There are fewer mechanical issues to address because the system is operated from a set of controls. There’s also virtually no risk of operational misuse and damage. You can’t accidentally drive an automated loading system off the dock. Automated systems do require regular servicing, but this can be easily planned for and budgeted into your initial investment.

4. Reduces Labor Costs

One of the most obvious reasons to invest in loading dock automation is the significant reduction in labor costs and associated expenses. There’s no question that the initial investment in automatic loading dock systems is significant. It requires the purchase of the equipment as well as the installation costs and the testing. There’s also an adjustment period where new implementation policies will need to be worked out. However, once the process is in place and operational, it will start earning a payoff right away.

Warehouses with automatic loading systems don’t require as many workers involved across all aspects of warehouse operations. Automation eliminates the need to double-handle goods, reducing the number of human touch-points. Managers won’t need to hire and retain as many forklift operators and shippers and receivers. Instead, managers can redeploy their talent to focus on higher-value work, such as quality control processes and continuous improvement. Warehouse automation also improves employee morale. Companies that invest in more productive systems can retain employees better because innovation becomes part of the company culture.

After investing in automated loading dock systems, warehouses can begin to earn a return on their investment in a matter of months or a few short years. Most of the return on investment comes from reduced labor costs and more efficient production.

5. Increases Throughput

With automated loading systems, warehouses can increase their throughput and overall production capacity. Each production cycle becomes more efficient because it maximizes the number of pallets processed. What may have previously taken an hour, now takes a few minutes. Production happens faster and can happen in higher volumes at a more consistent pace. This makes it easier to manage production rates as well as customer expectations because the automated process is so dependable. With automated loading and unloading, trucks also spend less time sitting idle. For third-party logistics (3PL) companies, it’s critical to the business model that trucks spend as much time as possible in a productive capacity. Automation allows for more shipments in a single day, maximizing the volume that each loading dock can handle.

Whether you’re looking at a semi- or fully-automatic component of the loading process, automation reduces or eliminates operator waiting time. With freezer spacer removal systems for cold storage facilities, moving loads from the freezer to the machine happens in rapid succession due to a more automatic process. There’s no need to wait for a material handler to move loads. During a shift, this efficiency can add up. Warehouses with more efficient production processes can take on more customers and fulfill more needs, creating opportunities for more profit.

Automation is also much more scalable than manual production. With automation, it’s just as cost-effective to increase production as it is to decrease it. During peak periods, many warehouses scramble to scale up their operations to accommodate higher throughput. They need to invest in additional material handling equipment, implement new processes for increased capacity and, of course, hire additional workers all to keep up with demand. With automation, the system is already implemented, and higher volumes of loads are much easier to handle.

Benefits of Automated Loading Systems

6. Prevents Repetitive Motion Injuries

Warehouse managers need to be making constant tweaks to increase productivity, and they need to look at more efficient ways for humans to move and handle goods with less wear and tear on the body. Repetitive motion injuries are a common concern in the warehousing sector. They occur when workers perform repetitive physical tasks over a long period, eventually leading to musculoskeletal disorders (MSDs) such as tendonitis and chronic pain. When workers suffer MSDs, it can cause them to miss work or require them to be moved to limited duties. This potential disruption in workplace productivity and impact on human health is why many warehouse managers today look for ergonomic solutions to prevent MSDs in their employees.

Reduce Worker Repetitive Motion Injuries in the Warehouse

Automation is one of the universal cures for MSDs because it removes much, if not all, of the physical responsibility that workers have for moving goods themselves. Rather than performing the physically strenuous tasks involved in the unloading and loading process, workers can simply operate and control dock automation systems, which perform all the physical work for them. As an ergonomic warehouse solution, automatic loading can mitigate or eliminate the costs associated with MSDs, such as downtime or workers’ compensation payments. Dock automation can also reduce costly turnover and all associated costs involved when employees are lost due to permanent injury.

7. Optimizes Space Utilization

Operating a warehouse incurs a high overhead cost. The larger the warehouse, the more expensive it is to operate. Large warehouses naturally store more goods, which all carry holding costs. Large warehouses also need more staff, equipment and materials, which can cause the operation to run less efficiently than necessary. One cost-effective way to maintain better profit margins is to reduce or maximize warehouse space. A smaller space forces businesses to run a more lean operation and focus on ways to tighten up turnaround times. If your goal is cut down on unnecessary warehousing costs, automation is a viable long-term solution to maximizing space utilization.

When a warehouse operates using automatic loading systems, the entire loading and unloading process becomes more efficient. You require less warehouse space to store goods because there’s a more concentrated flow of goods. The economies of scale that automation provides means that you can process a higher volume of goods in less time, so you don’t need to hold as much stock at any given time. Automated loading docks allow your warehouse to move to a just-in-time (JIT) inventory management system whereby you receive and ship goods only as you need to. Because there’s faster inbound and outbound goods transportation, warehouses don’t have to worry about carrying overstock.

Optimize Space Utilization and Organization in the Warehouse

Additionally, automated loading docks solve a problem that many warehouse operators face when they have less efficient loading systems. Without automation, warehouses require multiple loading docks, each designated to loading or unloading or select categories of goods or destinations. With automation, the entire loading and unloading process is much faster and more streamlined, meaning you can get by with fewer loadings docks, less space and a more cost-effective operation entirely.

8. Reduces Product Loss

Product loss in warehouses occurs when goods become spoiled, contaminated or damaged. Over a year, damaged products can end up costing the company a significant amount, especially when handling a high volume of goods. It makes prudent business sense for warehouse managers to have a continuous improvement process in place that analyzes product loss and devises solutions for how to mitigate it. Reducing product loss starts by understanding how goods get damaged in the first place.

Unless there’s a natural disaster or emergency incident, most product loss is caused by mishandling goods. Generally, this happens when there’s a misuse of material handling equipment. Even experienced forklift operators can make mistakes and cause damage to the equipment and the products they’re moving. Sometimes, forklift operators may not be properly trained or experienced enough, so investing in a solid forklift operator training program is crucial.

Causes of Product Loss in the Warehouse

Another factor that increases the risk of product loss is the multiple human touches goods encounter throughout the supply chain. In the typical warehouse, goods might get seven or eight touches throughout the production process, meaning there are multiple opportunities for goods to become lost, contaminated or damaged. With automation, there are multiple controlled steps in place that minimizes the amount of human handling products undergo. An automatic loading system minimizes the number of touches that a product needs because material handling is now supported by a system of conveyors and other equipment. Additionally, automated loading and unloading handle products in a safe and controlled way. When loading products, the automated system loads pallets and goods into trucks in a uniform and even way. The pallets are stable and their weight is evenly distributed so there’s less risk of product falling or getting damaged.

9. Decreases Freight Costs

With manual loading practices, a lot of cubic space can be wasted in the truck through improper stacking and space utilization. By manually loading goods, you risk improperly organizing pallets and boxes, creating unnecessary gaps and holes that could be filled with more product. The more product you can get into one truckload, the more cost-effective transportation becomes. With the rising costs of freight, it’s critical to maximize each load. Additionally, the tightening restrictions on driving times also pose another challenge in making freight as efficient a possible.

Decrease Freight Costs Through Improved Organization and Stacking

With loading dock automation, you can ensure that the cubic space of every truck is fully used. Automated loading technology has advanced vision guidance. The controls directly guide goods to be stacked in uniform rows from floor to ceiling, fully taking up all the trailer or truck space available. Getting more goods into one truckload helps to cut back on the number of trips required to distribute goods. Ultimately, automated loading helps to save on freight costs, truck and trailer wear and tear, fuel costs and labor expenses.

Choose Cherry’s Industrial for a More Efficient Warehouse

For all warehouse managers, streamlining processes is critical to maintaining profits and maximizing productivity. In any given warehouse, there are plenty of opportunities to improve current practices to make them more efficient, safer and cost-effective. A more efficient warehouse starts with your loading and unloading processes. With today’s automated solutions, you can speed up your production times, maximize your labor budget, protect your people and products, keep operational costs down and optimize your overall warehouse performance.

At Cherry’s Industrial Equipment, we provide high-quality material handling and warehousing equipment designed to maximize productive work. Automated solutions can help speed up simple, repetitive tasks, saving you a massive amount of time. Stretch wrapping machines from Cherry’s automatically wrap pallets and goods to secure and stabilize quickly them and eliminates time-consuming hand-wrapping. To boost picking productivity, we offer sanitary and durable plastic pallets and convenient automatic pallet dispensers for faster pick rates. Our industrial pallet changers are a safe and easy way to securely lift, tip and transfer loads effectively without risking damage.

For cold storage warehouses and cold chain 3PLs, our freezer space removal systems help streamline loading processes by combining loads and changing out pallets quickly. Our PSR model maximizes efficiency in frozen food and cold storage environments by reducing unnecessary manual labor and improving production output.

For more information on how Cherry’s Industrial Equipment can help enhance both safety and productivity in your workplace contact one of our representatives today. Call us at 1-800-350-0011 or contact us online.

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