Processes That Make Technology Work
Automated warehouse processes are often technically sound – yet practically inefficient. The issue rarely lies with the technology itself, but rather in the lack of proper process design: handovers, buffers, timing, sequencing – nothing fits together. BNDA Solution designs, evaluates, and integrates processes that make automated systems truly work. From picking strategies to conveyor systems. Visual. Understandable. Actionable.
Where Processes Fail in Practice
• Packing processes go unquestioned
• Conveyor systems, AMRs, manual carts – how do I move goods through the warehouse?
• Robotic cells operate individually – but not in sync with the system
• The warehouse is overloaded – smart replenishment strategies needed
• WMS & ERP – where are the limits?
Result: High effort despite costly automation.
What We Do
Process Analysis & Mapping
We capture the current state visually and with data – as a foundation for every improvement:
• Comprehensive logistics data analysis
• Zoning plans & process flow diagrams
• Process times & travel paths
• Bottlenecks, backlogs, redundancies
Development of Tailored Process Architectures
We don’t recommend standard solutions – we build a modular process toolkit, tailored to:
• Order structure
• Item profiles
• Warehouse geometry
• Team structure & shift model
Possible Strategies:
• Pick & Pass for high order density
• Batch picking for high repetition rates
• Hybrid processes with time- or order-based switching
Integration & Visualization
• Positioning automation based on takt logic
• Restructuring material flow
• Integrating carton erection and labeling into takt
• IT integration: interfaces between ERP, WMS, and control systems
• 3D layouts for alignment with teams and suppliers
Your Benefits
• Shorter paths, fewer handovers, more stable processes
• Reduced errors and idle times
• Less stress during peak periods
• Better control and scalability
• Higher team acceptance through clear processes
Project Example
Industry: Medical technology, growing online sales Initial Situation: Manual pick & pack processes, no conveyor system, packing in a separate hall Result: +40% faster order processing, -3.2 FTEs per shift
BNDA Measures:
• Switch to Pick & Pass with 3 stations
• Implementation of dynamic conveyor system
• Integration of automatic carton erector
• WMS/ERP coupling via middleware
You’re already automating – but your processes remain analog? Then let’s close the gap: between technology, people, and management.