Bottleneck in logistics is a process step that inhibits the throughput of the entire system. It can manifest itself in various places - at the unloading of pallets, during picking, in the internal transport section or when data is exchanged between IT systems. If one element stops even for a moment, a domino effect is inevitable.
Typical examples of bottlenecks in logistics:
- Too slow unloading of pallets, which delays the entire receiving area.
- Insufficient number of picking stations, causing congestion during peak hours.
- Narrow transportation corridors or lack of flexible means of handling pallets.
- Data inconsistency between warehouse and ERP systems.
- Errors in labeling and identification of goods, which are common causes of complaints.
Each of the described places is a potential brake that reflects on the cost and timeliness of deliveries. Therefore, it is worth asking yourself:
How to diagnose bottlenecks in time and what to do so that they don't slow down the entire warehouse operation? Find the answers below.
How to eliminate bottlenecks in logistics?
Bottlenecks are not always due to human error. Often, they are caused by technological limitations, insufficient infrastructure or a lack of integration between different stages of the process. So let's take a look... and here unfold you can refer precisely to the tools I mention in the following paragraphs
Automation of repetitive operations
Bottlenecks are not always the result of human error. Very often they are due to technological limitations, insufficient infrastructure or lack of integration between process steps. Let's take a look at tools to eliminate the most common barriers:
- Depalletizers automate pallet unloading and reduce receiving times
- Automatic labellers Reduce errors and standardize the marking of goods.
- Pick-to-Light Systems Reduce picking time and increase picking precision.
Improving internal transportation
Transportation of goods between zones is a sensitive area where bottlenecks happen most often.
- Accumulation conveyors act as a smart buffer - they allow to temporarily stop the goods without stopping the whole line.
- Roller turntables allow changing the direction of pallet transport without reloading and additional maneuvering.
- Transport carts up to 60 m/min synchronize the flow of pallets between parallel lines.
- Transport elevators Provide efficient vertical movement in multi-level facilities.
Intelligent storage systems
Lack of space in a warehouse is a classic example of a bottleneck. This is when solutions that increase the use of available space become crucial:
- Storage stackers automate pallet retrieval and storage, increasing throughput.
- Mezzanines and multilevel shelving units allow maximum use of space without expanding the hall.
IT systems integration and traceability
Not every bottleneck is visible to the naked eye. Often the biggest outages are due to a lack of up-to-date data that delays decision-making. The solution is:
- Integration of WMS and ERP systems ensures that information is consistent and up-to-date in real time.
- Traceability systems (backward, process, forward and external) give full control over the flow of goods and enable rapid response to problems.
Solutions tailored to your warehouse
Each industry has its own tipping points.
- W food industry The priority is to maintain the right temperature and use the FEFO principle to avoid waste.
- W e-commerce What matters above all is the efficient handling of large order volumes and the rapid sorting of shipments.
- W pharmacy There is no room for compromise - the most important thing is full batch traceability and compliance with strict quality standards.
However, these are just examples. In practice, each warehouse operates differently and faces its own challenges. That's why at Intralog we don't start with ready-made prescriptions, but with a careful look at processes. We analyze flows, look for the actual causes of downtime, and only then select technologies and systems that really improve daily operations and allow the warehouse to operate more efficiently.
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