Please Allow Me to Introduce Myself – Systems Integration Group
Discover what systems integration really means for warehouses, from mechanical and controls to software and electrical, and how to find the right partner.
By SOLUTIONS COMMUNITY
Updated:
A warehouse with streamlined and smooth-flowing operations doesn’t happen by accident, nor does it happen overnight. It takes a lot of moving parts (literally!) to create a warehouse that has their operation applications in synch, applications like conveyors, sorting systems, robotics systems, and forklifts. Ask any warehouse manager how they got to this point and they will say it was with the help of their systems integration company.
What is systems integration?
Systems integration is the combining of different warehouse hardware applications that have different software languages and codes into one interconnected and intercommunicating system. While this can be a difficult task, a systems integration company will help you achieve this goal. A systems integration professional works with warehouses to see what they currently use, figures out how to get different systems to communicate, and, if necessary, recommends additional systems to make the warehouse more efficient. The goal of the systems integrator is three-fold – to create a warehouse with better efficiency, better data collection, and more predictability. The components that go into systems integration are: Mechanical Systems, Control Systems, Software, and Electrical/Safety. Let’s examine these components in more detail.
Mechanical
Generally, when a systems integrator is called in, that warehouse has already amassed a significant amount of mechanical equipment, i.e., hardware. The issue is getting those different pieces of equipment made by different manufacturers to communicate with each other to create one cohesive warehouse. These warehouses are called brownfields because systems have already been built and put in place. Sometimes there is the opportunity for warehouses and systems integrators to build a brand-new warehouse (greenfield) and create system integration from the beginning.
A systems integrator is NOT typically an equipment hardware manufacturer. A systems integrator is a company that provides all necessary engineering, equipment, installation, controls, and integration software to help all these different systems talk to each other and sends all that information to one location, making operations easier to monitor. An ideal systems integrator will go into a warehouse to make sense of what the business already has, determine if anything needs to be replaced or added, and then prescribe the appropriate level of automation for the system. The systems integrator’s goal is to make full use of what the warehouse already has.
Although systems integrators don’t typically manufacture equipment, they are an important conduit to manufacturers, especially for warehouses looking to expand or upgrade their facilities. A top-notch systems integrator will have established relationships with a variety of manufacturers and vendors to help find the right hardware solutions. Having these vendor relationships also provides client benefits such as better equipment pricing and terms.
Controls
The reason warehouses need a systems integrator is because warehouse applications are highly specialized, therefore, vendors often focus on one type of system. Typically, there are vendors that only make conveyor systems, vendors that only manufacture print-and-apply machines, that only make robotics, sorting equipment, forklifts, etc. And each company has their own operating systems (controls and/or software) for their specific equipment. Because of this, the conveyor is unable to “communicate” with the printer, and neither can communicate with the sorting system. A systems integrator will provide a software platform that not only helps these different pieces “talk” to each other but can also put all the data collected from these systems into one easy-to-access location. This is possible because operating systems usually have the same base structure in their software’s application programming interface (API) allowing systems integrators to build a bridge between these platforms.
Software
This is what systems integrators are brought in to do. They develop software platforms to build a bridge between all the different systems. Most importantly, they put all the data from each system into one location, making it easier to track warehouse performance and provide maintenance visibility and support. And not only do they provide the software, but a systems integrator will also provide maintenance and service programs after integration to keep things running smoothly.
Systems integrators generally have their own WES (warehouse execution system) and WCS (warehouse control system) software. WCS is the platform that controls the automated equipment in the warehouse while WES organizes warehouse operations. If a company is a systems integrator that doesn’t have their own software systems or sends it out to a third party, there could be complications down the road.
Electrical/Safety
An important component of warehouse applications is electricity. Without it, the machines can’t move. An ideal systems integrator will be UL certified, meaning they can install electrical systems, build electrical panels, and run cables throughout the warehouse to the stringent UL standards. They will ensure the right number of outlets and panels located in the right places and, more importantly, having enough power to run everything.
All of these components together help with safety. Equipment and systems that are working together and communicating with operations will help maintain safe operations, minimize breakdowns that can lead to accidents and unscheduled downtime, and provide a sense of security in the building.
Working Together
A systems integrator isn’t just a vendor you hire; they partner through the execution of the project and stay engaged to support post commissioning. They are a trusted partner who works with you. Like any partnership, each side has a role. A key role of the systems integrator is to visit the facility to see existing operations firsthand and gather knowledge about each application. They listen to what the client wants to achieve, and they provide expertise on each of the four integration components. An ideal systems integrator will also handle all components under one umbrella. And once the system is built, the integrator stays on to provide continued service, assist with maintenance, answer questions, and help with upgrades.
The client must also participate in their own integration. They need to let the integrator know what they want to accomplish and they need to be honest about what their existing equipment can and can’t do. The most important thing a client can do is provide the integrator with information in a timely manner when requested. Any delays in receiving information will lead to delays in the integration.
How to Find the Right Systems Integrator
Warehouses need to vet potential systems integrators much like a homeowner would vet a contractor remodeling a kitchen. That begins with a series of questions. It is important to ask the following:
Can I get everything I need from this systems integration company: mechanical, controls, software, and electrical?
Will I have to find other subcontractors/vendors?
Do they have existing relationships with multiple hardware manufacturers and vendors?
Do they provide support and maintenance? Do they have 24/7 support available?
Do they have their own WES/WCS software?
Finally, contact references to learn what others have experienced with the company.
MHI’s Solutions Committee Can Help
Finding the right systems integrator isn’t easy, but MHI and the Solutions Committee can help. There are over 100 group member companies already vetted and willing to work with you to find the solution to integrating your warehouse.
Contributor: Jeff Marchlewski, Systems in Motion
Reviewed by the Solutions Community Systems Integrators Committee
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