Warehouse Operations Automation Course

Lesson 1 • Warehouse Operations Fundamentals

Core warehouse functions—receiving, storage, picking, packing, shipping—are defined and linked to automation opportunities. Establishes vocabulary for the entire course.

Lesson 2 • Automation Maturity and Readiness

Introduces maturity models to assess current-state operations before selecting technology. Students evaluate readiness gaps and prioritization criteria.

Lesson 3 • Taxonomy of Automation Technologies

Classifies fixed, flexible, and autonomous automation across mechanical, software, and data layers. Provides a reference framework used throughout the course.

Lesson 1 • Inventory Control and Cycle Counting

Automates inventory accuracy through system-directed cycle counts, ABC classification, and discrepancy resolution. Directly supports picking accuracy downstream.

Lesson 2 • WMS Reporting and Analytics

Builds dashboards and KPI reports from WMS transaction data to monitor operational performance. Enables data-driven decisions for continuous improvement.

Lesson 3 • Inbound and Receiving Automation

Configures WMS-directed receiving, license plate tracking, and putaway rules. Reduces manual decision-making at the dock.

Lesson 4 • Outbound Order Management

Covers wave planning, order release logic, and cartonization within the WMS. Links order management to picking and shipping execution.

Lesson 1 • RFID Technology Principles

Explains RFID frequency bands, read range, and tag types for warehouse environments. Prepares students to evaluate RFID feasibility for specific use cases.

Lesson 2 • Barcode Symbologies and Standards

Compares 1D and 2D barcode formats, print quality standards, and global labeling conventions. Establishes the data-capture foundation for WMS and automation integration.

Lesson 3 • Mobile and Fixed Scanning Hardware

Covers handheld scanners, vehicle-mounted terminals, and fixed tunnel scanners used in warehouse workflows. Guides hardware selection based on task and environment.

Lesson 1 • System Integration with WMS

Explains warehouse control system middleware that translates WMS orders into conveyor and sorter commands. Students trace a carton from scan to sort destination.

Lesson 2 • Maintenance and Uptime Management

Establishes preventive maintenance schedules, fault diagnostics, and uptime KPIs for conveyor systems. Directly impacts throughput reliability in automated operations.

Lesson 3 • Sortation Technologies

Covers sliding shoe, pop-up wheel, tilt-tray, and cross-belt sorters and their throughput profiles. Students match sorter type to order profile and product characteristics.

Lesson 4 • Conveyor Controls and PLC Basics

Introduces programmable logic controllers, sensors, and zone control logic that govern conveyor operation. Bridges mechanical systems to software-driven automation.

Lesson 1 • AS/RS Control and WMS Integration

Covers warehouse execution system commands, crane scheduling algorithms, and WMS task interleaving. Students configure task sequences to balance throughput and travel time.

Lesson 2 • Storage Density and Slotting

Applies slotting logic, velocity profiling, and aisle configuration to maximize storage density. Directly affects AS/RS throughput and energy consumption.

Lesson 3 • AS/RS Technology Overview

Classifies unit-load, mini-load, vertical lift module, and shuttle-based AS/RS by capacity and speed. Sets the selection criteria used in later design exercises.

Lesson 4 • AS/RS Performance and Safety

Defines throughput metrics, aisle safety protocols, and emergency stop procedures for AS/RS environments. Prepares students for safe daily operations and audits.

Lesson 1 • Facility Mapping and Environment Design

Covers map creation, traffic lane design, and obstacle management for AMR deployment. Students design floor layouts that maximize robot efficiency and safety.

Lesson 2 • Fleet Management Software

Configures task dispatching, priority rules, and fleet monitoring dashboards in fleet management software. Links robot task execution to WMS order streams.

Lesson 3 • AMR Types and Navigation Technologies

Distinguishes AMRs from AGVs and covers SLAM, QR-code, and natural feature navigation methods. Provides the technical basis for deployment and environment design.

Lesson 4 • AMR Use Cases and Workflow Design

Applies AMRs to goods-to-person, zone-to-zone transport, and cycle count workflows. Students design task flows that reduce travel time and human walking distance.

Lesson 1 • Robot Cell Integration and OEE

Integrates robot cells with conveyors, WMS, and safety systems and measures overall equipment effectiveness. Students diagnose downtime causes and improve cell performance.

Lesson 2 • Industrial Robot Fundamentals

Covers robot arm types, degrees of freedom, payload ratings, and reach envelopes relevant to warehouse tasks. Establishes mechanical literacy for gripper and cell design.

Lesson 3 • Gripper and End-Effector Selection

Compares vacuum, mechanical, and soft grippers for varied SKU shapes, weights, and surface textures. Students match gripper type to product characteristics and cycle time.

Lesson 4 • Machine Vision for Picking

Introduces 2D and 3D vision systems for object detection, pose estimation, and bin-picking applications. Connects vision accuracy to picking success rates.

Lesson 1 • Continuous Improvement and Governance

Establishes governance structures, KPI review cadences, and continuous improvement cycles for sustained automation performance. Closes the course with an operational excellence framework.

Lesson 2 • Project Implementation and Go-Live

Manages site preparation, system acceptance testing, parallel run, and cutover planning for automation projects. Reduces go-live risk through structured validation steps.

Lesson 3 • Change Management for Automation

Applies stakeholder analysis, communication planning, and resistance management to automation deployments. Addresses workforce concerns and role transition planning.

Lesson 4 • Vendor Selection and RFP Process

Covers requirements documentation, RFP structure, vendor scoring, and reference site evaluation. Students draft an RFP for a defined automation scope.