Automation is as individual as the companies using it. Even automating individual process steps noticeably increases efficiency in the warehouse. Examples show how our brands Linde Material Handling and Dematic alleviate bottlenecks, reduce employee workload and increase process reliability.
2025-08-07
Warehouse automation is not an either-or scenario: Companies select the solution that best fits their needs from various levels of automation – whether selective, partially automated or fully integrated. At KION, we distinguish four levels of automation:
We highlight the components, technologies and system solutions behind the first two levels of automation – showing how our customers boost efficiency, transparency and future readiness in their warehouse and material flow processes. Part 1 of this series explains the fundamentals of on-demand automation. Part 2 of the series focuses on more complex automation solutions and their implementation.
Autonomous high-lift trucks (Linde L-MATIC) in use.
All transport and warehouse processes are carried out by employees using manually operated equipment such as forklifts. Many companies still operate this way, especially where throughput is low or maximum flexibility is required. Modern vehicles and ergonomic aids from Linde MH, such as the semi-automatic N20 SA order picker and digital assistance systems like Linde connect: enhance ergonomics, safety and efficiency even in these minimally automated areas.
The main advantage of predominantly manual warehouse operations is maximum flexibility with low investment – ideal for companies with manageable inventory turnover or highly variable requirements.
In the high-bay warehouse of Heidelberger Druckmaschinen.
Heidelberger Druckmaschinen AG implemented a new manual storage concept with our Linde MH brand : A high-bay warehouse with around 4,500 items is operated using reach trucks and order pickers from Linde MH. Ergonomic vehicles featuring sensor-supported driving assistance and lithium-ion technology ensure smooth operation. Picked goods are transported to production via logistics trains. This system reduces travel distances, boosts supply reliability and has been successfully enhanced with digital tools such as Linde connect:.
Pick-to-light displays make picking easier.
For the retail chain Claire's, Dematic implemented a manual picking system that uses pick-to-light displays, optimized storage zones and ergonomic workstations. Employees are guided through the picking process with light signals that increase accuracy and reduce errors. The system is complemented by Dematic Warehouse Execution software, which provides key performance indicators via dashboards for enhanced transparency. This solution demonstrates how manual processes can become significantly more efficient through targeted digitalization and ergonomic support.
Bottlenecks are specifically addressed with technology ranging from automated guided vehicles and on-demand conveyor technology to automated storage systems that handle entire pallets or containers. Technologies used include autonomous mobile robots (AMRs), simple automated transport vehicles (ATVs such as Linde L MATIC), and automatic storage systems like Pallet Shuttle Storage. Advantage: This targeted automation – especially in transport and storage applications – lowers employee workload, enhances process stability and reduces errors. Automated transport vehicles and conveyor technology can typically be integrated quickly without major modifications.
Autonomous Linde vehicles streamline material transport at Poloplast.
At plastic pipe manufacturer Poloplast, two autonomous Linde L-MATIC vehicles ease internal material transport . They travel autonomously along predefined routes between production and the warehouse, independently detecting obstacles. Thanks to its easy integration and natural navigation, the solution was implemented without major modifications. The vehicles operate around the clock, significantly boosting the flow of materials and reducing operational errors.
Dematic has partially automated the internal transport processes at the Vorarlberg Milch dairy in Austria using AGVs that operate between ripening rooms and treatment stations. The vehicles follow virtual routes within a complex, dynamic facility and receive live data through a central control system. Barcode tracking, automatic destination assignment and secure loading processes ensure top hygiene standards and consistent process quality in the fresh products sector.
The KION Group offers automation solutions that can be flexibly tailored to the needs of companies. The advantages: Enhanced efficiency, improved ergonomics for employees and increased safety. The KION Group supports companies at every stage – from manual processes to full automation. Part 1 of this series explains the fundamentals of on-demand automation. The KION Group assists companies in selecting the ideal solution – scalable, modular, and always focused on delivering genuine added value. This enables companies to gradually transition into automation. Discover how to enhance your warehouse’s efficiency and optimize your processes. Part 2 of the series focuses on more complex automation solutions and their implementation.
