Launched at Ocean Business 2025, the solution enables both traditional and uncrewed vessel operators to streamline data operations, unlock operational insights, and improve global collaboration between vessels and shore-based teams. Geomatics is the latest addition to Kongsberg Discovery’s Blue Insight ecosystem, delivering smarter data workflows and real-time visibility across diverse ocean sensor networks.

Welcoming the ‘data librarian’

As ocean activity accelerates and initiatives like the UN Decade of Ocean Science target efforts to map the seabed by 2030, the ability to manage vast volumes of complex data – across a myriad of sensors, formats and protocols - is more critical than ever.

Modern survey vessels, often operating as part of multi-platform fleets with AUVs and USVs, generate massive data streams from a wide range of environmental, meteorological and acoustic sensors.

“Survey teams are busy enough without wrestling with incompatible formats and fragmented systems,” comments Audun Berg, EVP of Kongsberg Discovery. “Geomatics takes the hassle out of data management, giving users a single, intuitive platform that lets them focus on the mission – simplifying complexity and optimising efficiency.

“Think of it as the perfect librarian for ocean data: one that makes sure all data is correctly filed, easy to find, and displayed clearly, for all relevant stakeholders. We see this as the revolution in data management operators need to meet increasingly ambitious surveying and research goals.”

Geomatics operates as the first Blue Insight product, collecting a suite of software services on the platform to simplify ocean data management. Benefits include centralised data collection and logging from all onboard and remote sensors, automatic cataloguing and indexing to prepare data for exploration and analysis, and seamless data distribution to mirrored cloud environments or other data management systems.

Visualisation of data is a key strength - empowering easier, quicker and more powerful insights – with both real-time and historical data georeferenced in dashboards, maps, and time series viewers, and a high degree of customisation available (allowing users to filter and tailor displays according to specific needs).

The Geomatics architecture is AI and machine learning ready, building a foundation for the integration of digital twin technology and further enhancing processing capabilities. A new Analytics product is also under development, allowing for automated processing and in-depth data analysis.

Seamless collaboration

“Geomatics has been built to enable excellence in the demanding domain of ocean research and surveying,” explains Berg. “It adds huge value by streamlining data collection, delivering real-time dashboard insights, and making data globally accessible, empowering better collaboration. From environmental monitoring to large-scale seabed mapping, Geomatics takes the pain out of juggling huge quantities of data, for faster, more efficient and accurate ocean discoveries.”

Early adopters have already been putting Geomatics through its paces ahead of today’s wider market launch, with the solution now being rolled out to several research vessels, including R/V Anna Weber-van Bosse, operated by NIOZ, the Royal Netherlands Institute for Sea Research, and Statsraad Lehmkuhl for the One Ocean Expedition (OOE).

Commenting on the latter, Geir Pedersen, researcher and member of OOE’s Scientific Committee, explains: “The One Ocean Expedition is once again setting sail and will be relying on Geomatics to catalogue the vast quantity of scientific data we collect with Statsraad Lehmkuhl. It’s vital to get a complete record of the data, while we keep control of data quality under the voyage. Researchers will benefit from seamless data access both onboard and onshore as they progress their vital work.”

Geomatics is available as of now. Survey and research teams can explore the platform by visiting this link and signing up for early access. As part of the roll-out, Kongsberg’s existing Marine Data Management (MDM) product will be merged into Geomatics. Existing customers will be offered an attractive migration package to upgrade to Geomatics, or continue with technical support for a limited time.

www.kongsberg.com/discovery/

Augmented reality (AR) is no longer just a futuristic technology to monitor – it has become a powerful tool reshaping the manufacturing industry. From enhancing worker productivity to bolstering operational efficiencies, AR solutions are proving their worth across manufacturing environments. But what does the future hold?

These five key trends for AR in manufacturing in 2025 are not merely theoretical concepts or long-term visions. They represent the new and tangible advancements that users can experience and benefit from today, shaping the future of the manufacturing industry.

1. Flexibility in augmented reality hardware use

Gone are the days of being locked into one specific AR hardware provider. By 2025, manufacturers will enjoy increased flexibility in their choice of devices, effortlessly switching between AR platforms or systems. This interoperability makes AR adoption more scalable and cost-effective, providing businesses with the agility to leverage the best tool for every task.

Imagine using smart glasses for assembly operations one day and projection system the next – all without compatibility issues or extended downtimes. This ability to adapt seamlessly will empower manufacturers to maximise the value of their AR investments.

One of DELMIA’s Augmented Experience customers, a global leader in aerospace, provides operators with the flexibility to conduct quality inspections using either a tablet or a camera. This allows workers to select their preferred tool for each task, every day, based on their individual comfort and workflow. It’s a great example of adapting to user needs – whether it’s technological familiarity, ergonomic preferences like sitting or standing, or overall ease of use – ensuring seamless adoption of augmented reality solutions.

2. Leveraging Artificial Intelligence (AI) for smarter Augmented Reality (AR) applications

AR is a technology that increasingly depends on AI, and the two are becoming closely integrated. AR involves connecting the real world with the virtual, helping users understand their environment through localisation and contextual definitions. AI enhances this by analysing reality and interpreting environments at an advanced level, effectively aligning and synchronising the virtual twin of a product with the real world.

We anticipate a stronger reliance on AI, particularly for quality inspection applications. AR systems enabled with AI will identify defects much quicker and in a reliable way. Another area where AI is going to bring a lot of value is in its ability to improve tracking initialisation, enabling rapid and accurate alignment of the digital 3D data and the real part for straightforward visualisation of AR instructions.

AI’s role will go beyond troubleshooting or identifying flaws. Predictive algorithms and machine learning will enhance workflows, providing operators with actionable insights in real time. This integration will make AR tools more intuitive, reducing complexity while improving outcomes.

3. Automated augmented reality work instruction creation

Creating AR work instructions for manufacturing processes can be labor-intensive, especially in the case of frequent changes in the 3D model and configurations of the parts. However, automation is set to streamline this in 2025. Advanced software will generate AR-guided instructions directly from CAD models and processes definition, supporting automated updates. Additionally, AI will contribute to enhance processes and work instructions definition, further accelerating the automation of the content creation process.

This innovation will significantly reduce implementation time while ensuring instructions are always up-to-date with the latest designs or processes. Workers will benefit from accurate, clear, and visually immersive directions that reduce errors and improve precision on the shop floor.

4. Enhanced integration of augmented reality with connected technologies

AR in manufacturing is expected to make a significant advancement through greater integration with third-party technologies, resulting in a more enhanced and immersive experience. This development will go beyond simply displaying work instructions and will allow for increased interaction with work cells and the surrounding environment.

For instance, we anticipate seamless connections to smart tools and voice modules, which will expand the possibilities for connected workers. Voice modules will allow workers to interact with AR systems simply by speaking, enabling hands-free operation. Meanwhile, smart tools – like sensors, torque wrenches, or IoT-enabled equipment – will feed real-time data into the AR interface, creating a unified and smarter workspace. Leveraging the AI capabilities mentioned earlier, these technologies become more intuitive by integrating multi-modal interactions through vision (AR) and dialogue (voice), paving the way for a virtual assistant.

This level of connectivity will reduce cognitive workload, enhance comfort, and allow workers to focus on decision-making rather than repetitive tasks. The result? Improved productivity and safer, more intuitive work environments.

5. Improved and extended collaboration thanks to augmented reality

As the adoption of AR systems continues to expand in manufacturing, together with the use of the virtual twin, we are witnessing an exciting trend towards improved and extended collaboration. With an increasing number of AR platforms interconnected, professionals will soon collaborate seamlessly across multiple devices, operators, and even machines, such as robots. Powered by the virtual twin, which serves as a reference point and ensures digital continuity, this connectivity will enable real-time information sharing, synchronised actions, and coordinated decision-making, significantly boosting productivity and efficiency.

By connecting multiple AR devices, several operators can work together on the same task simultaneously, improving coordination. For example, technicians could collaborate on complex assembly processes, such as those in aerospace or automotive manufacturing. This trend not only increases productivity but also enhances teamwork, reduces errors, and is particularly valuable in industries where precision and collaboration are critical.

Enhanced AR systems collaboration can also foster cross-departmental coordination for faster problem-solving. For instance, if an operator identifies a defect, they can immediately report it to a quality inspector, who can then provide real-time AR guidance for diagnosis and correction. This rapid response cycle helps resolve issues quickly and efficiently, ensuring smoother production.

This real-time collaborative model could also extend to interactions with production teams spread across multiple sites, further strengthening the agility and overall efficiency of the manufacturing process.

Why these trends matter for manufacturing professionals

Understanding these trends isn’t just about having a competitive edge – it’s about preparing for the transformation that AR will bring to manufacturing workflows. Whether you’re leading a digital transformation initiative, managing IT strategies, or heading AR based projects, staying ahead of these trends will be critical for driving progress.

Hélène Druet is senior offer marketing manager at DELMIA

www.3ds.com/products/delmia

With businesses unable to rely on national infrastructure improvements alone, they must proactively assess their connectivity strategies. A slow, inconsistent network costs time and money, making it essential for organisations to evaluate whether their current connectivity meets their needs.

Rather than waiting for national infrastructure improvements, businesses can explore reliable, secure, and high-speed connectivity options tailored to their operational needs.

“Businesses should consider dedicated leased lines to ensure uncontended, high-speed connections that deliver consistent performance,” says Clinton Groome, chief executive officer at Espria. 

“Unlike shared networks, these solutions provide reliability and stability, keeping operations running smoothly. Leased lines represent the gold standard for business connectivity, offering dedicated, high-speed, and uncontended internet access with maximum reliability. For businesses requiring fast broadband, FTTP (Fibre to the Premises) is an excellent option, while SOGEA (Single Order Generic Ethernet Access) provides efficiency by eliminating the need for a traditional phone line.”

Businesses benefit from adopting a structured approach when evaluating connectivity solutions. Mobile data, including 4G and 5G, can play a role but should be viewed as a backup rather than a primary solution.

“5G holds great potential, but inconsistent coverage and speed limitations mean it may not always be the best choice for business-critical operations,” Groome explains.  

“For areas with fewer connectivity options, SOADSL (Single Order ADSL) can provide a solution, though businesses may find greater benefits in higher-performance alternatives. For organisations looking for a scalable and secure alternative to consumer broadband, business-grade Ethernet offers excellent performance and security.”

Recent studies have shown that companies investing in dedicated connectivity solutions have experienced up to a 40% reduction in downtime and improved operational efficiency.  

“As businesses continue to embrace digital transformation, reliable and secure networks are becoming a fundamental pillar of success.”

The case for proactive investment

Connectivity is no longer just about speed – it’s about security, stability and business continuity. Relying solely on public 5G networks or outdated broadband solutions can introduce performance issues, security risks and operational downtime.

Groome continues: “Network resilience is critical. Businesses must ask themselves: would an outage impact critical operations? If the answer is yes, then it’s time to re-evaluate connectivity strategies. Security should also be a top priority. Public networks can expose sensitive data, making businesses vulnerable to cyber threats. Investing in secure, private connectivity solutions is essential to safeguarding data and maintaining trust.

“With digital transformation accelerating, scalability is another key consideration. Can your current infrastructure support future growth? If not, proactive investment is needed to avoid costly disruptions. By reviewing their connectivity strategy now, businesses can future-proof their operations and unlock new opportunities for innovation.”

Taking the next step towards a resilient future

With UK 5G coverage still developing, businesses have the power to take control of their connectivity rather than waiting for infrastructure improvements.

Groome concludes: “Failing to upgrade connectivity now could mean falling behind competitors, losing customers and exposing sensitive data to cyber risks. Businesses that act today will be the ones that thrive in a digital-first economy. Whether it’s upgrading existing networks, adding redundancy measures, or exploring dedicated connectivity options, investing in a robust, future-proof solution will ensure businesses remain productive, competitive and secure. 

"The question is: what steps is your business taking to stay connected and prepared for the future?”

www.espria.com

Since its launch in February 2023, Nexus has attracted over 30,000 registered users, enabling each of them to access innovative solutions, training and tailored support that tackle long standing industry challenges.

Hexagon has been expanding Nexus’ product portfolio to empower users at every stage of the workflow:

• Hyperscale computing for simulation: Nexus Compute offers on-demand access to Hexagon’s best-in-class CAE simulation solvers, regardless of company size.
• Cloud-native applications: Solutions such as Virtual Test Drive X (VTDx) – Hexagon’s IF award-winning automotive software testing SaaS – simplifies ADAS and autonomous vehicle software testing through thousands of orchestrated cloud simulations.
• Accessibility-boosting UX: From the outset, user experiences, such as Metrology Reporting, are designed to save experts time on quality deviation reporting while allowing non-experts to quickly interpret data with accessible web-based reporting and cloud collaboration.
• Productivity-Boosting AI: Automated programme generation for machine tools (ProPlanAI), metrology (Metrology Mentor), and CoPilot customer support is empowering desktop software users to boost personal productivity and helping employers achieve operational excellence and retain vital knowledge.
• Connecting workflows and processes: Highly flexible and open cloud integration enables effortless data sharing between software tools, IoT sensors and machines, helping organisations to overcome technical barriers and build efficient engineering and manufacturing workflows, connect quality into the digital thread and empower data-driven operations with connected worker applications.

Nexus is built on a legacy of innovation, combining Hexagon’s decades of industry expertise with Microsoft’s latest cloud and AI technologies. The platform’s open and flexible data-centric architecture offers customers several distinct integration options to connect a wide variety of third-party applications, from simple file exchange to real-time data sharing powered by Microsoft’s Fluid Framework. This versatility enables seamless connectivity across the digital thread, linking CAE tools, simulation and process data management (SPDM), and PDM/PLM systems of record that have traditionally operated in isolation with production systems, shopfloor IoT and quality data sources.

Stephen Graham, executive vice president and general manager of Nexus at Hexagon, stated: “There’s growing recognition that successful digital transformations start with people and what they are trying to achieve. Regardless of where they are in the value chain, Nexus is helping these people to improve their work and how they collaborate with their peers. It’s exciting to see this approach gain momentum and envision how we can further amplify individual’s efforts as we ramp up developments in workflow automation and AI.”

As Nexus continues to evolve, customers across automotive, aerospace and advanced manufacturing are already seeing tangible benefits, from streamlining simulation and testing to improving production efficiency and knowledge sharing.

Jinhwa Lee, research engineer and part leader at Hyundai Motor Company commented: “At Hyundai Motor Company, we are leveraging Nexus with Hexagon’s mature and trusted CAE suite to accelerate our development cycles, optimise engineering performance, and drive a more agile, data-driven approach to vehicle development. Building a cloud-based vehicle development platform is our key strategy goal and we are incorporating the innovative approach and open integration Nexus offers to achieve that vision.”

Gabe Schulze, industrial engineer at Path Machining, said: “ProPlanAI has been a game-changer. It excels by capturing the best practices and expertise we have built as a company and applying them to new parts. We don’t need to learn all about AI – we simply use ESPRIT EDGE, and the cloud app refines our processes over time. Nexus is more than just a tool; it’s an evolving system that helps us capture know-how, maximise productivity, and improve operational excellence.”

Nexus is an open platform for connecting with third-party vendors, making new technologies and solutions accessible to Hexagon’s user base. Software partners include Acerta LinePulse, CASTOR, Instrumental, JITbase, MachiningCloud, Moldex3D, OCTOPUZ and Zaptic. Integrations and data libraries include Solera VTD Catalog, Arcane Tech (for Cabinet Vision), and material databases through Materials Connect.

Nexus now seamlessly connects with Hexagon’s popular PC-DMIS, VGSTUDIO MAX, and QUINDOS software, further integrating quality data into the digital thread, and helps users of its ESPRIT EDGE, EDGECAM, DESIGNER and VISI CAD/CAM software tools improve shopfloor productivity. These initiatives, among others, are setting the stage for increased use of quality control and measurement data to improve quality faster, optimise manufacturing processes and improve products and customer satisfaction.

Hexagon’s Nexus platform is an evolving ecosystem that promotes access to the newest technologies that enhance productivity, foster collaboration, and enables iterative digital transformation for organisations of all sizes across the manufacturing value chain where 500,000 people use Hexagon’s technologies in every industry daily as part of their chosen technology stack.

nexus.hexagon.com/

The tape acts as both a thermal and electrical insulation barrier, offering ample protection for extreme thermal environments that characterize spaceflight, Mach speeds, and battery thermal runway.

AeroZero Tapes, already proven in launch vehicles, satellites and electric aircrafts, provide aerospace engineers, product designers, manufacturers, and R&D teams advanced thermal management solutions for critical applications where failure isn’t an option. With their ultra-thin, lightweight, and flexible design, these tapes are ideal for applications where space is limited, and factors like weight reduction, material thickness, safety, and ease of application are critical factors.

Tim Burbey, president at Blueshift, says that the thermal protection industry has evolved rapidly in recent times: “As vehicle designers strive to save weight and minimise the footprint of their designs, they face significant challenges that drive the need for innovative solutions. This has led to the development of our next-gen AeroZero® Tapes that unlock new performance possibilities for applications ranging from Low Earth Orbit (LEO) satellites to Advanced Air Mobility (AAM) aircraft.”

Blueshift primarily provides AeroZero® Tapes in commercially available formats, offering a range of configuration options to meet specific application needs. Available in various thicknesses and widths, AeroZero Tapes are designed to tackle unique thermal challenges that other tapes on the market cannot. Additionally, the convenient ‘peel-and-stick’ technology streamlines integration and enhances overall production efficiency.

“With virtually limitless design possibilities, AeroZero Tapes help enhance product safety and protect brand reputation,” adds Burbey. “Our tapes offer safe and reliable thermal protection for components that require precise, high-performance materials.”

For more information on AeroZero Tapes, visit www.blueshiftmaterials.com/az-tape/ or watch the launch video.

AeroZero Tapes can be purchased directly through Blueshift’s website or through electrical contractor Digi Key. 

Originally intended to expand in phases over several years to reach nearly 100,000 bins and 71 robots, Bleckmann decided to bring forward the entire expansion to the end of 2024.

This rapid growth underscores the AutoStore empowered by Kardex solution’s ability to optimise warehouse operations, significantly reduce labor requirements, and maximise space utilisation—offering seven times the efficiency of manual fulfillment methods. With the extension, Bleckmann enhances its services by offering a multiclient AutoStore solution to multiple customers, setting itself apart with this unique selling proposition.

The initial Kardex AutoStore system, which went live in late 2023, was fully operational in just five months from order placement, seamlessly integrating with Bleckmann’s logistics network. The expansion from 25,000 to 100,000 bins was completed without downtime or operational disruption, demonstrating the system’s modular and scalable nature. Facing increasing order volumes and labour shortages, Bleckmann needed a high-efficiency solution to enhance fulfillment speed and optimise warehouse space. The Kardex AutoStore system met these demands with minimal energy consumption (ten robots use the same amount of power as a single vacuum cleaner) aligning perfectly with Bleckmann’s sustainability goals at its 100% solar-powered facility.

The initial system comprised a 25,000-bin AutoStore grid, 24 robots, and five ergonomic ports. Since implementation, order cycles have accelerated by 60%, throughput has increased, and picking errors have decreased, resulting in greater customer satisfaction and retention. The expanded system now features seven Carousel Ports, with five additional pick ports in development ahead of Black Friday 2025. Kardex’s innovations have further enhanced the AutoStore system. The dedicated Kardex Warehouse Control System (WCS) has streamlined operations, while an automatic Robot Cleaning Station ensures system reliability. Additionally, a multiple conveyor port enables simultaneous replenishment across three bins, drastically improving inbound processing efficiency.

Eric Ebbers, senior sales manager at Kardex, stated: “We are thrilled to support Bleckmann in pushing the boundaries of warehouse automation. The Kardex AutoStore solution is designed for scalability, allowing Bleckmann to start small and expand seamlessly. This partnership is a testament to the power of innovation and collaboration.”

Kevin Paindeville, director ofiInnovations and warehouse solutions at Bleckmann, added: “The flexibility and scalability of the Kardex AutoStore system have exceeded our expectations. We’ve been able to ramp up to full capacity in just one year without disrupting operations, reinforcing our commitment to efficiency and customer satisfaction.”

Jens Hooyberghs, automation project manager at Bleckmann, emphasised: “The system automatically prioritises high-demand items for faster dispatch, making a significant difference during peak sales periods. Kardex AutoStore is proving to be a key asset in making our operations more efficient, sustainable, and future-ready.”

www.bleckmann.com

The company can now synthesise incident data collected by the advanced sensors in new cars, such as emergency braking, sharp steering or manual intervention. This allows Volvo Cars to probe, reconstruct and explore in new ways to better understand how incidents can be avoided.

This is possible thanks to an advanced computational technique called Gaussian splatting, which can create a vast amount of realistic, high-fidelity 3D scenes and subjects from real-world visuals. The virtual environment can, for example, be manipulated by adding or removing road users and changing the behaviour of traffic or obstacles on the road to generate different outcomes.

Such a technique allows Volvo to expose its safety software to all types of traffic situations, at a speed and scale not possible before. The company can now develop software that also works well in complex, rare yet potentially dangerous ‘edge cases’, and reduce the time it takes to expose our software to edge cases from months to days.

“We already have millions of data points of moments that never happened that we use to develop our software,” says Alwin Bakkenes, head of global software engineering at Volvo Cars. “Thanks to Gaussian splatting, we can select one of the rare edge cases and explode it into thousands of new variations of the scenario to train and validate our models against. This has the potential to unlock a scale that we’ve never had before and even to catch edge cases before they happen in the real world.”

One part of the puzzle

Volvo Cars uses virtual environments alongside real-world testing for software training, development and validation because they’re safe, scalable and cost-efficient. The virtual environments are developed in-house in collaboration with Zenseact, an AI and software company founded by Volvo Cars.

This project is part of a PhD programme for leading Swedish universities to explore whether neural rendering techniques will be integrated into future safety initiatives. The study is sponsored by Wallenberg AI, Autonomous Systems and Software Program (WASP).

A history of using data to improve safety  

Volvo Cars has a long history of using data and advanced technologies to enhance safety. Data collected by the Volvo Cars Safety Research Team has played a crucial role in the development and testing of some of the world’s most prominent safety features.

In the 1970s, Volvo Cars started leveraging data to improve safety thanks to its Safety Research Team. In the early days, the team arrived at the scene of accidents with measuring tapes, assessing skid marks and other crash indicators. The data and knowledge gathered from the accidents have inspired numerous life-saving innovations, such as the Whiplash Injury Protection System and Side Impact Protection System. New advanced technology now allows us to be even smarter with how we use data to prevent risky situations.

Integration of NVIDIA technology

Volvo Cars can explore technologies such as Gaussian splatting thanks to the recently expanded relationship with NVIDIA. The new generation of fully electric cars, built on NVIDIA accelerated compute, collect data from various sensors to understand what’s happening in and around the car better than ever before. An AI supercomputing platform, powered by NVIDIA DGX systems, contextualises this data, unlocks new insights and trains future safety models. It will improve and accelerate the development of artificial intelligence. This supercomputing platform is part of a recent investment of Volvo Cars and Zenseact to set up one of the largest data centres in the Nordics.

The exploration of Gaussian splatting and generative AI forms part of Volvo Cars’ presentation at the NVIDIA GTC conference. The presentation is accessible live or on demand here.

Currently, BSI IS recruiting for new members to support the development of machinery standards for the polymer industry. The committee covers all aspects of the industry including injection, blow and extrusion moulding, ancillary equipment including mould clamping systems as well thermoforming and cutting equipment.

CEN/CENELEC and ISO standards are a vital part of keeping people safe in the workplace, ensuring that machinery and equipment is designed and constructed to be safe to use. With our new relationship with Europe, it is now more than ever that we need to have a say in the development of safety standards as while they are developed by the EU they will be adopted by the UK, often without modification and we will have to accept the requirements.

The committee usually meets twice a year and meetings are held virtually. There is the opportunity to be invited as a guest to see the work of the committee before committing.

So, if you have technical knowledge in any of these areas and would like to be involved – please contact: csc@bsigroup.com

The challenges facing warehouse and supply chain logistics professionals are complex and interconnected, from skilled labour shortages and rising business costs to changing regulatory demands, shifting consumer expectations, and geopolitical tensions causing shipping and supply issues.

While addressing these problems may seem insurmountable, smart technology and automation can provide the direction for change, helping warehouse managers to address these pressing issues holistically whilst also ensuring alignment with broader supply chain traceability goals.

Global business challenges

If the last few years have been dominated by an increasingly challenging business climate, 2025 looks set to continue that trend. As Deloitte’s 2025 manufacturing industry outlook states, “manufacturers are expected to continue to face a challenging and uncertain business climate due to a combination of higher costs, potential policy changes following the US and global elections, and geopolitical uncertainty”.

Raw material and other input costs are expected to grow, increasing the cost of business operations, while finding and retaining skilled workers will remain problematic. Anticipated policy changes following global elections and other geopolitical events may also impact supply chains, demand, and long-term investment in manufacturing. Changes to trade policy and tariffs could affect international regulations, drive up raw material and component costs, and have ripple effects throughout the supply chain.

At the same time, consumer expectations for faster delivery times, ‘Amazon-like’ distribution capabilities, and greater supply chain transparency, are adding to the pressure on supply chain and warehouse leaders.

This complex set of interdependencies is prompting businesses to look for ways to increase productivity and do more with less: producing and shipping goods faster without increasing costs. This calls for operational agility and efficiency, with optimised workflows and near real-time visibility of supply and demand to manage disruption and shortages and fulfil orders seamlessly and transparently.

One could be forgiven for likening this to an impossible challenge; however, in today’s modern era, help is at hand in the form of smart technology and automation.

The case for warehouse automation

Businesses have been investing in warehouse automation for decades, using technology to automate routine, repetitive, and manual processes, including picking, palletising, data entry, transfer and analysis, stocktaking, quality control, and shipping.

This trend has increased significantly in recent years with technological advancements. In 2023, 60% of warehouse managers reported plans to increase their automation budgets by 20% in 2024, while globally, the warehouse automation market is expected to grow from $19.9 billion in 2022 to $54.6 billion by 2030. Similarly, the warehouse robotics sector is growing at a rate of 20–25% annually, according to Statista, while McKinsey reports that robot shipments are expected to increase by >50% per year through to 2030.

The benefits of warehouse automation are significant. These include reduced human error, increased productivity and efficiency, and – critically – access to real-time data to unlock visibility of what is happening both within the warehouse and in the upstream and downstream supply chain. Indeed, it is this real-time data that interlinks and underpins solutions to the operational challenges leaders face today.

The warehouse management system, or WMS, is at the heart of warehouse automation. To successfully and holistically increase productivity, optimise operational agility and efficiency, and meet consumer and regulatory demands, businesses must ensure that the correct data feeds into, through, and out of the WMS.

Machine-readable codes and identification technologies, including GS1 QR codes, barcodes, and RFID tags, can help to enable seamless data flow from the production line into the warehouse. At the same time, vision systems can be used not only to verify the accuracy of these codes but also to ensure reliable data transfer and effective sorting of products. Within the warehouse, automated barcode and RFID scanners can further facilitate data transfer – speeding up stocktaking and enabling traceability of products moving through the system. Warehouse managers can also elect to utilise robots, cobots, and safe print and apply labellers to assist human workers with routine tasks like packing, picking, sorting, and pallet labelling – further streamlining processes and reducing the risk of injury. All this can be complemented by many and varied smart technologies, such as adaptive coding and marking systems, pallet and parcel dimensioners, and variable height vision systems equipped with ‘liquid’ lenses to manage diverse package sizes and ensure precise measurements for efficient shipping.

When properly integrated, smart systems and technology utilised on the production line and automated warehousing solutions will complement one another and support the flow of data into the warehouse and out into the wider supply chain – a crucial link in the chain for complete supply chain traceability.

A warehouse manager’s ultimate goal may be to achieve a fully automated ‘lights out’ warehouse, a smart and dynamic facility where streamlined data flows in and out and which incorporates the use of artificial intelligence (AI) and/or machine learning to analyse data patterns, predict potential issues, and further streamline operations.

But – how do we get there? With EY citing that between 30–50% of robotic process automation projects fail globally, and Gartner predicting that at least 30% of generative AI projects are likely to be abandoned after proof of concept by the end of 2025, taking steps to identify and address pitfalls early is fundamental.

Making automation work

The three most commonly cited barriers to warehouse automation are poor planning, lack of integration, and workforce readiness. Businesses need to plan and tread carefully – as unclear business value and misaligned or incompatible systems will inevitably lead to workplace confusion, data silos, a lack of communication, and the inability for data to flow seamlessly. And, of course, organisations should not underestimate the importance of workforce readiness. The move to automation will demand a digital fluency and familiarity with information and processes that may need traditionally trained production line workers to be upskilled before embarking on a project of such significance.

Fundamental steps to take are:

• Plan and execute carefully. Understand your business case and key success metrics. Start slowly: pick off your ‘low-hanging fruit’ that will deliver early success and inspire confidence. Monitor and adapt.
• Collaborate for success. Identify suppliers that are willing to work together to ensure that their solutions can integrate with your existing systems, particularly your WMS.
• Align with your upstream supply chain and production partners to ensure the optimum quality of readable barcodes, 2D codes, data coming into the warehouse.
• Align with downstream supply chain partners for complete transparency throughout the wider supply chain, particularly within a retail/consumer environment.
• Bring your workforce along with you. Identify potential skills/digital literacy gaps and invest in training upfront. Involve your workforce in potential applications for automation where early wins can be achieved.

The warehouse is arguably the lynchpin in today’s supply chains, the single point where upstream and downstream distribution points collide. Ensuring warehousing efficiency, productivity, and operational visibility is key to an organisation’s ability to navigate – indeed, conquer successfully – modern business demands.

Yet the challenge is complex. Working with a trusted partner with experience and expertise in providing production line and warehousing solutions designed for integration and data transfer will set you on the right path and support your direction of change.

Toby Odlin is head of group logistics and supply chain projects, and Andreas Olsson is global sector manager logistics and distribution at Domino Printing Sciences; Paul Stinson is sales director at Lake Image Systems

www.domino-printing.com

AtkinsRéalis has been working at Sellafield to deploy a customised Boston Dynamics Spot quadrupedal robotic ‘dog’ on site, working alongside employees to inspect areas, capture data and carry out tasks in hazardous areas for the last two years. This trial successfully established highly secure networks and tested the ability to operate robotics like Spot on site, remotely, from a location outside the site license boundary.

AtkinsRéalis worked closely with Sellafield’s remote technology group in the months building up to the trial to put in place the necessary digital and cyber protocols to enable the safe and secure operation. Pete Allport, Head of Remote Technology at Sellafield, operated Spot from AtkinsRéalis’ immersive room in nearby Whitehaven, live-streaming footage from a non-critical area on the site.  

This kind of virtual site access is already deployed by AtkinsRéalis for major construction projects to record and view footage across sophisticated and secure networks for teams across locations. It can unlock significant time and cost savings and reduce the need for additional personnel on site: for example, it can allow specialists off-site to view data and swiftly make decisions to inform and speed up complex operations.  

Richard Brook, technology solutions lead for decommissioning at AtkinsRéalis, said: “Sellafield has pioneered the adoption of technology across its operations, and this latest milestone is another step forward for the role of robotics in decommissioning. Virtual site access is already being used in the delivery of major infrastructure programmes: this trial is a big step towards unlocking its benefits for nuclear licensed sites without compromising safety or security.”

The NDA group is utilising technology and innovation to transform how nuclear decommissioning is delivered and this approach could be applied across other nuclear licensed sites to deliver benefits across the wider NDA group. 

Deon Bulman, ROV Equipment Programme Lead at Sellafield said "This successful trial marks a significant milestone in our journey towards integrating advanced robotics into our operations at Sellafield. The ability to remotely operate robotic systems like Spot demonstrates how digital innovation can enhance safety, efficiency, and decision-making on nuclear-licensed sites. By collaborating with AtkinsRéalis, we are exploring cutting-edge solutions that not only support our decommissioning mission but also pave the way for future advancements in remote operations."

AtkinsRéalis digital nuclear solutions include robotics for use across the nuclear lifecycle, from remote data capture (such as the use of a Spot robot to remotely inspect Calder Hall) to robotic arms for glovebox operations and industrial-scale robots to sort and segregate nuclear waste. Their use can boost workplace safety – keeping humans out of high-risk areas and identifying potential hazards – but can also unlock significant time and cost efficiencies, automating processes to free up the human workforce to focus time on high priority, highly-skilled activities.  

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