Automation Solutions at the Loading Dock

As industries evolve, automation has become a cornerstone of sustainable growth, safety and efficiency. From financial institutions to fast-food kitchens, every workplace is moving toward a lower-touch, higher-efficiency model. Manufacturing facilities and warehouses are no different. Businesses embrace automation to help combat supply chain disruptions, increased demands, labor shortages, outdated facilities and constant pressure to stay competitive.

One overlooked area where automation can make a significant impact is the loading dock — your facility's gateway for most goods. 

Considerations for Automating the Loading Dock

Automating other areas of your facility without addressing the loading dock can create bottlenecks. This has a ripple effect — inefficiencies even flow back upstream to affect your automated operations.

With forklifts crossing a single dock position as many as 300 times per day, disrupting the flow can have serious consequences for your bottom-line. And because each position presents its own set of unique challenges, loading dock automation is not a one-size-fits-all solution.

Before you being any automation project, align internally on the goals driving your automation planning. 

Understanding your “why” before getting to your “what” and “where” establishes a foundation for success. Questions about business goals, current challenges, future need and other considerations will help guide your path to success.

These questions are tricky to navigate for first-time pilot projects, though — so it’s important to bring in industry experts early to help. Integrators will assist you in discovering your “why,” which drives your project’s success.

Once you have your answers, the following considerations will help you plan for loading dock automation implementation.

1. Type of Automation Technology

At the loading dock, automation can take the form of extendable conveyors, automated trailer loading systems (ATLS), automated guided vehicles (AGVs), autonomous mobile robots (AMRs) and more. Today, industries are seeing a growth in Automated Guided Vehicles (AGVs) usage for trailer loading and more.

A Research and Markets report estimates that the global AGV market will develop at a 10.2% average yearly rate of compounded growth through 2031. According to the report’s summary, this rapidly growing adoption is driven by labor cost savings, lower priced units, consistent performance and other AGV benefits.

One main challenge with the rise of AGVs, though, is ensuring compatibility with loading dock design, equipment and controls application. This type of automation requires a consistent environment for sensors to function properly. Successful integration calls for connected communication between the loading dock equipment and AGVs to load and unload efficiently. Several loading dock solutions are on the market to support the growing adoption of AGVs and other automation technologies.

2. Loading Dock Design

A quote attributed to Eliyahu Goldratt reminds us, “Automation is good, so long as you know exactly where to put the machine.”

All material transfer process demands and flows are unique. The loading dock must ensure a seamless transfer into and out of your facility. When planning for an automation project, seven key variables factor into your loading dock design:

• Trailer positioning
• Trailer stabilization
• Drive approach design
• Dock door size
• Dock door center lines
• Loading dock height
• Pallet load configurator

Plan your unique loading dock design early. Waiting until the end of an automation project can lead to costly delays and rework. Alterations to new construction can cost tens of thousands of dollars per dock, add months to your project and greatly extend the time needed to recoup your automation implementation investment. To help ensure a successful completion of a project from start to finish, carefully consider the partners you’ll need.

3. Loading Dock Equipment Selection

If choosing to upgrade or remodel an existing operational loading dock to accommodate for automation, current dock design and equipment may hinder the performance of automated solutions. For example, a dock leveler must match an AGV’s specification to help prevent instability and sensor problems. Additionally, a trailer should be supported by a stabilizing vehicle restraint (and in the case of dropped trailers, a trailer stand) which helps minimize vertical and horizontal movement. A trailer lift can increase productivity with loading and unloading processes and ensure accurate, centered alignment.

If not addressed, improper loading dock design and equipment application can lead to operational downtime, ruined product, or damage to the Automated Guided Vehicle. Considering an AGV can cost up to $500,000, rushing a retrofit to save time can do more harm than good. Especially to your ROI...

Remember, automation is a journey for long-term success. Explore implementation in phases — you can start small and scale up. Having clear KPIs for what success looks like for your facility matters no matter what, though, so ensure each step can be accurately measured.

4. Loading Dock Controls Applications

In automation, communication between loading dock equipment and AGVs is crucial. Fully documenting your current processes and the level of desired automation (or human involvement) will help establish the controls application that’s right for your facility today and tomorrow. This connection of shared data between equipment and technology can help improve safety and efficiency, while facilitating preventative maintenance knowledge to make better informed decisions. To best utilize this data, pair controls with a digital platform that aids in proactive versus reactive planning for increased throughput, maximized efficiency, less unplanned downtime and mitigated safety incidents.

Rite Partner of Choice

We cannot stress enough how strong partnerships can make or break a project. They play a key role in the coordinated effort of successful loading dock automation. Bring together the collective expertise of loading dock experts, AGV suppliers, loading dock control applications and Warehouse Management Systems (WMS) integrators to ensure a holistic approach to the project's success. Tailoring automation solutions to the facility's needs and ensuring effective communication between loading dock equipment, programmable logic controllers (PLCs) and AGVs is a critical step to avoid costly redesigns and operational hiccups.

As companies embrace this transformative technology, it's important to plan thoroughly, collaborate with the right partners early and adapt equipment effectively. As the leader in loading dock equipment since 1965 and with a track record of many successful automation projects, Rite-Hite is committed to guiding businesses through their automation journeys by expertly understanding:

• Critical loading dock design considerations
• Loading dock equipment application criteria
• Loading dock controls applications
• Industry supply chain technologies

If you have questions, consult an expert. Rite-Hite is here to advise you on the loading dock design considerations above and any other unique concerns you might have for your entire warehouse.

Learn More About Rite-Hite Automation Solutions