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Implementation of Automated Microfulfillment Center with Integrated WMS and Robotics

firstlinesoftware.com

Manufacturing

Food & Beverage

Pharmaceuticals

Electronics

Retail

Operational Inefficiencies in Existing Warehouse Infrastructure

Existing 6,000m² warehouse with automated machinery (shuttles, conveyors, label scanners, robot cranes) suffered from suboptimal space utilization, limited communication between systems, and capacity constraints that hindered scalability and productivity.

About the Client

International supplier of paper, corrugated, and compact cardboard packaging with 6,500+ employees across 70 plants in 20 countries

Key Project Goals

Enhance warehouse mobility and productivity through automation
Improve system-wide communication between automated machinery
Optimize space utilization through Microfulfillment Center design
Reduce product damage through automated palletizing processes
Support 50% future growth capacity

Core System Requirements

Real-time data exchange between WMS and PLC systems
TCP/IP protocol-based communication architecture
PLC emulation for risk-free system testing
Dynamic routing and topology configuration
Inventory tracking with pallet-level precision

Technology Stack

viadatWMS (customized)

TCP/IP communication protocol

PLC (Programmable Logic Controllers)

Microfulfillment Center automation equipment

Robotics integration framework

System Integrations

WMS-PLC interface via TCP/IP telegrams
Robotics equipment control systems
Label scanner data integration
Conveyor belt automation synchronization

Non-Functional Requirements

Scalable architecture for 50% growth
Real-time system responsiveness
High-availability communication protocols
Modular design for future equipment additions
Fault-tolerant data exchange mechanisms

Expected Business Impact

Implementation will deliver 30-40% operational efficiency gains through optimized space utilization, reduced product damage rates by 25%, 50% increased storage capacity, and enable seamless scalability to support future growth while maintaining real-time inventory transparency across 15,000+ SKUs.