The modern warehouse environment looks little like the warehouses of 10 years ago. In today’s warehouse, automated systems dominate, leveraging robotics and a wealth of data to speed up everyday operations. Warehouse staff are constantly on the lookout for technologies and solutions that will help make the most of every minute and every square foot of their space.
Machine vision (MV) systems are changing the dynamics of the warehouse landscape. This technology is quickly becoming essential for warehouses to incorporate into their operations. By mimicking human sight, MV systems enable warehouses to see, identify, and make informed decisions with incredible precision. Machine vision enhances key processes like picking, packing, and palletizing, driving efficiency and reducing errors to near zero. Add in cost-saving benefits and reduced reliance on manual labor, and it’s easy to see why so many leaders now find machine vision so compelling.
These systems can deliver major warehousing benefits but must be integrated strategically and be guided by expert insight. Otherwise, this technology could potentially prompt problems and even produce a decidedly unimpressive return on investment (ROI). To reveal both the potential and the challenges of MV systems, we’ve provided a deep dive into top warehousing applications below, along with how to overcome frequently cited obstacles.
Understanding Machine Vision
Machine vision brings the power of human sight to computerized systems. Incorporating cameras and signal processing, this cutting-edge technology can analyze and interpret a wealth of visual data. Unlike humans, however, machine vision works 24/7 and can integrate seamlessly with a variety of other advanced solutions. In the warehouse, MV can most frequently be found working alongside machine learning (ML), radio-frequency identification (RFID), robotics, and Warehouse Management Systems (WMS).
Key Machine Vision Applications in Warehousing
Machine vision holds great promise for boosting data-driven strategies across industries, but it is especially promising in the context of the modern, automated warehouse environment. Integrated with the right solutions, MV can transform warehouse operations, bringing efficiency, accuracy, and agility to any warehouse workflow. That being said, MV currently delivers the greatest impact in a few key areas, which often rely on visual input (and perception) but may not be able to make full use of human employees at all times.
Quality Control
Machine vision systems can reveal product defects, including some that could potentially be missed by the human eye. As images are captured, they are analyzed by advanced algorithms, which are purposefully trained to highlight anything that deviates from the “ideal” for specific items, packages, or even pallets. Often, this means indicating scratches or product discoloration, although issues with packaging may also be evident.
Depending on the warehouse or application, detected issues may result in the automatic rejection of an item deemed lacking in quality — or this may prompt a manual inspection from a human employee. Either way, MV-aided quality control processes are more efficient but do not sacrifice accuracy in their quest to improve throughput.
Pallet and Depalletizing Operations
MV systems can reveal where space is available and even guide robots in delivering pallets to designated locations. Similarly, this technology can prove useful for depalletizing, as MV systems recognize the various items situated on pallets and can move them accordingly. This works especially well when unusually stacked items are involved, as the advanced systems integrated with MV can aid in analyzing complex configurations. This should reveal which strategies will prove most impactful, even when dealing with mixed-product pallets.
Packing Bench
Packing benches streamline various packaging and shipping processes, but when they incorporate machine vision, already profound benefits take yet another step up. For example, MV can improve labeling procedures, with automated labeling systems ensuring that all information featured on labels is correct. These systems also confirm that the right products are packed at the right time. Additional quality inspections may occur at this point, providing another chance to catch defects before they cause problems with customers.
Warehouse Operations Optimization and Workflows
In all areas of the warehouse, machine vision promises to optimize workflows, ensuring that previously time-consuming tasks can be completed quickly and with minimal hassle. Such optimizations run the gamut from palletizing to quality control but may even involve routing or predictive maintenance.
Fixed industrial scanners are widely used when the advanced complexity of smart cameras is not needed. With high-speed barcode scanning, fixed industrial scanners provide fast and accurate data capture with durability, reliability and versatility promising to dramatically improve many critical warehouse workflows.
Machine Vision in Inventory Management
Often used to verify stock levels, machine vision can promote advanced inventory management strategies, in which real-time insights reveal when restocking is required. In fact, this approach can even trigger automated restocking procedures. This is far more efficient than traditional (and manual) stock counts — and human errors are far less likely. This also represents a considerable improvement over traditional scanning processes; machine vision systems are capable of reading barcodes, so there is no need for manual scanning.
Benefits of Machine Vision in Warehouse Environments
No matter where it is implemented or how extensively it is used, machine vision promises many exciting advantages, several of which allow already impressive automated solutions to improve even more. Frequently cited advantages include:
- Improved accuracy: Human error is a common source of trouble in everything from palletizing to picking, packing, and shipping. Today’s MV systems, however, prevent many types of errors, such as issues with manual stock counts or incorrect labeling. Machine vision brings not only a proactive approach to error prevention but also ensures that any errors that do occur are promptly caught via enhanced quality control mechanisms.
- Greater operational efficiency: Simply put, MV systems (especially working alongside robotics) are extremely efficient. These systems are capable of analyzing and interpreting complex data at extraordinary speeds, even providing real-time data to facilitate quick adjustments.
- Enhanced customer satisfaction: Today’s customers have incredibly high expectations — and they will not stick with brands for long if they suspect that their orders will not be properly (or quickly) fulfilled. Machine vision systems offer powerful quality control, along with the chance to speed up operations so that fulfillment can occur in record time.
Challenges and Considerations of Machine Vision Integration
Machine vision solutions may be exciting, but they can present distinct challenges that must be proactively addressed. Top sources of concern include:
- Integration with WMS: Seamless integration is a must, but unfortunately, not all MV systems are compatible with all WMS software. Even when compatibility is a perk, configuration can prove challenging, as complex algorithms must be set up — and specific parameters must be defined for inspection purposes. If this is not handled properly (preferably by an expert) at the outset, errors are likely.
- Measuring success via metrics: Although machine vision systems promise to boost efficiency and reduce certain operational expenses, these solutions come with upfront investment. To verify that they achieve the desired return on investment (ROI), it is important to continually track metrics such as downtime, order fulfillment time, inventory accuracy, and return rates.
Future Trends and Advancements
Machine vision technology has undergone dramatic advancements in recent years, but this is about to take yet another step up as accompanying AI technology continues to improve. Deep learning, in particular, is expected to unleash a whole new world of possibility, driving greater accuracy in MV-oriented quality control. These systems will boost object recognition, prompting greater precision when highlighting defects and also helping systems navigate a far wider array of products or situations.
Peak Technologies Can Help
Machine vision has a powerful role to play in modern warehousing operations, but it will not reach its full potential unless these systems are strategically planned and implemented. Our experts at Peak Technologies can provide valuable guidance, including a personalized approach to ensure that Machine Vision systems meet the unique needs within each warehouse environment.
As a certified Zebra machine vision integrator, Peak offers expert installation, along with end-to-end integration solutions. Contact our team to learn how machine vision products and solutions can transform your operation.
Sources
https://www.techtarget.com/searchenterpriseai/definition/machine-vision-computer-vision
