The ideal way to replace avalanche transceivers

Results of a study and an individual roadmap

Why replacing warehouse management systems (WMS) is crucial for modern intralogistics

Warehouse management systems (WMS) are a central component of modern intralogistics. They are designed to make workflows efficient and transparent, optimize the flow of materials and enable end-to-end digitalization of warehouse processes. In practice, however, it is often the case that existing systems no longer meet these requirements - whether due to a lack of automation functions, insufficient system integration or inadequate support. Changes in business processes and increasing performance requirements as part of Logistics 4.0 are also leading many companies to consider replacing or modernizing their WMS.

Unitechnik's white paper answers the most important questions about changing software, highlights optimization potential in warehouse management and provides practical recommendations for selecting the right solution and for a structured replacement of the existing system.

The WMS is the central point for managing all logistics processes. © Unitechnik

Your contact person

Ein freundlich lächelnder Mann mittleren Alters mit kurz geschnittenem, dunkelbraunem Haar trägt ein dunkelblaues Sakko über weißem Hemd und steht vor einem hellen, unscharf dargestellten Hintergrund.

Matthias Spies

IT-Consulting and Sales UniWare

T +49 2261 987-358
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Survey results and white paper as PDF download

Many warehouse management systems are reaching their limits in the course of the digitalization and automation of intralogistics. Outdated systems make it difficult to integrate modern technologies and hinder efficient process control. Replacing the existing warehouse management system gives companies the opportunity to modernize their logistics software and create the basis for networked, future-proof intralogistics.

A survey conducted by Unitechnik in July 2021 among around 60 participants from various industries shows that many companies see the modernization or replacement of their WMS as an important step towards greater efficiency and transparency. At the same time, however, there are still concerns - for example, about possible start-up problems or a time-consuming migration process.

The results of the Unitechnik study "Is it worth replacing the warehouse management system?" offer valuable insights into current trends and success factors for a system change - and show how companies can successfully take the step into the digital future.

Ergebnisse der Umfrage zur LVS-Ablösung
Studie (German)
Ergebnisse der Umfrage zur LVS-Ablösung
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The ideal way to replace avalanche transceivers
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The ideal way to replace avalanche transceivers
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Initial situation - How German logistics companies feel about replacing their warehouse management system

Replacing the existing warehouse management system (WMS) can be a decisive solution for many intralogistics companies in order to modernize processes, increase efficiency and create the basis for end-to-end digitalization of warehouse logistics. Nevertheless, many companies are hesitant to take the step of replacing their WMS - often due to uncertainty or concerns about the possible consequences.

The most common concerns include the fear of start-up problems, business interruptions or even complete standstills in the material flow during the changeover. Many managers are also deterred from replacing an outdated system by the fear that the software change could be complex, time-consuming and associated with a lack of transparency in project management.

Yet it is precisely these concerns that are usually manageable with structured project planning, clearly defined interfaces and an experienced WMS service provider.

In order to better understand the actual market situation, Unitechnik Systems GmbH conducted a targeted survey: "Is it worth replacing the warehouse management system?" in July 2021 among around 60 participants from various industries, it became clear how companies currently feel about modernizing their warehouse management system, what experience has already been gained and which hurdles are perceived as particularly critical in WMS migration.

Trends in warehouse logistics - where the greatest optimization potential lies in the WMS

The result of the survey: even though two thirds of respondents are satisfied or very satisfied with their current WMS, 72% of companies would like to make adjustments in the short to medium term. Half of them already have concrete plans to change or upgrade their WMS. e.g.

Fig. 1: Satisfaction of companies with their current WMS. © Unitechnik
Fig. 2: Necessity of adjustments to the current WMS. © Unitechnik
Fig. 2: Necessity of adjustments to the current WMS. © Unitechnik
Fig. 3: Willingness to change or upgrade the avalanche transceiver. © Unitechnik
Fig. 3: Willingness to change or upgrade the avalanche transceiver. © Unitechnik

Overview - These types of warehouse management systems are currently in use

We look at four different types of warehouse management systems.

WMS function in an ERP system
In this variant, no standalone warehouse management system is used. Instead, management is carried out via integrated functions of an ERP system such as SAP ERP, Microsoft Dynamics or Infor. This solution is particularly suitable for smaller or less automated warehouses. However, if the requirements for warehouse technology, conveyor technology or process automation increase, many companies are faced with the decision of whether to expand the ERP system with customer-specific modules or introduce a specialized WMS. A dedicated warehouse management system usually offers more transparency, efficiency and interface diversity for modern intralogistics.

Standard WMS as out-of-the-box software
The most cost-effective form of warehouse management system is standard software with a fixed range of functions. It is immediately ready for use ("out of the box") and does not require a long implementation phase. However, adaptations to customer-specific processes or automated systems are hardly possible. Companies have to adapt their logistics processes to the existing functions. This makes this solution particularly suitable for simple warehouse structures, but less so for complex, automated material flows or dynamic supply chain environments.

Standardized WMS with flexible customer adaptation
This type of system combines standardized basic functions with the option of individual extensions. It therefore offers a good balance between costs, flexibility and future-proofing. Customer-specific adaptations enable precise mapping of existing logistics processes, while standardized modules provide a stable basis. Thanks to open interfaces to ERP, MES or WMS systems, the WMS can be optimally integrated into existing IT structures and thus supports the digitalization and automation of intralogistics.

Highly individualized WMS
The highly individualized warehouse management system is tailored to the specific requirements of a company. The proportion of individual programming is particularly high here. This allows the software to be adapted precisely to existing warehouse technology, conveyor technology and production processes. This solution is ideal for complex, automated logistics centers with high performance requirements. It enables maximum efficiency, scalability and data integration across all levels.

More than half of those surveyed already use specialized WMS systems that can be individually adapted to their logistics processes. This flexibility is a key success factor for companies that want to make their intralogistics future-proof, data-based and efficient.

Challenges and risks when replacing warehouse management systems

For more than 50 percent of respondents, the risk of downtime in logistics is the main reason for refraining from replacing a WMS. 45 percent believe that the changeover process would take too long. However, the issue of resources also plays an important role: 45 percent do not have enough manpower available for a project to change the existing WMS. In contrast, only a quarter of respondents cited the higher costs of a new system as an argument.

Fig. 5: Reasons not to replace an avalanche transceiver. © Unitechnik
Fig. 5: Reasons not to replace an avalanche transceiver. © Unitechnik

Reasons for modernizing and replacing outdated warehouse management systems

1. the provider is crucial
The original provider of the warehouse management system (WMS) is no longer on the market - this is just one reason why companies are looking for an alternative. They are also often dissatisfied with the previous WMS service provider because the system is not being developed further or there is a lack of consulting expertise. Changed license models with higher costs or a lack of contact persons also lead to frustration. Many companies are therefore looking for a modern provider that combines warehouse technology, conveyor technology and software integration.

2. system is no longer state of the art
An outdated operating system, missing interfaces to ERP or MES and expired maintenance contracts are often reasons for replacing a WMS. No company can afford to take a security or failure risk in a central area such as intralogistics. Timely modernization improves warehouse management, reduces risks and creates the basis for digitalization and efficient conveyor technology.

3. reduce uncontrolled growth
Structures that have grown over the years lead to confusing processes: many interfaces, different systems and personnel-dependent expertise. Modern WMS software reduces this proliferation, standardizes processes and integrates warehouse technology and material flow into an efficient overall system. The aim is an all-in-one system with clear processes and a central database.

4. getting costs under control
Rising operating costs are a frequent trigger for replacing a warehouse management system. High license fees, expensive adaptations and high administration costs lead to inefficient structures in the long term. By using a modern WMS with integrated warehouse technology and automated processes, operating costs can be sustainably reduced. Standardized functions and flexible interfaces also reduce the effort required for maintenance, servicing and system expansions.

5. requirements have changed
Changing business processes, new technologies and higher performance requirements pose major challenges for existing warehouse management systems. If the current WMS is no longer able to efficiently map the material flow or the production connection, modernization becomes unavoidable. A scalable system with modern software architecture and seamless integration into the existing warehouse technology ensures greater flexibility and future-proofing.

6. data is the raw material of the future
In modern intralogistics, data is the basis for efficiency and competitiveness. New warehouse management systems record and analyze operating data in real time, creating transparency in all processes. Intelligent evaluations allow material flows, stock levels and system availability to be optimized. Data-supported warehouse management also forms the basis for continuous improvement in conveyor technology.

Fig. 6: Motivation for replacing existing avalanche transceivers. © Unitechnik
Fig. 6: Motivation for replacing existing avalanche transceivers. © Unitechnik

The survey clearly shows that the most common reasons for replacing a WMS are technically backward or outdated systems. In particular, an outdated operating system, a lack of upgradeability and a lack of interfaces to other IT systems such as ERP, MES or WMS are cited. These deficits prevent the end-to-end digitalization of warehouse logistics and make it difficult to integrate modern automation solutions.

Changing requirements in intralogistics also play a key role. Today, companies want an intuitive warehouse management system that supports automated processes and enables a seamless connection to production.

As a result, the focus is increasingly shifting towards holistic process optimization - away from isolated software solutions and towards integrated material flow and warehouse management systems.

In contrast, classic cost issues were rated surprisingly low. License costs, maintenance costs or providers' hourly rates play a subordinate role in the decision for or against a WMS migration. The decisive factor is rather the functionality: the front-runner among the points of criticism is the lack of analysis options in the existing systems. Without modern data analysis, transparency in the warehouse and continuous performance evaluation, many companies lack the basis for sustainable optimization of their logistics processes and the next step towards Logistics 4.0.

Selection criteria for the right avalanche transceiver software and the right provider

These WMS features are in demand
When selecting their new WMS, companies should pay attention to a number of functionalities. Basically, all the pain points that prompted a change should be eliminated in the new WMS.

The most important basic requirement for a WMS is user-friendliness. In times of skills shortages and high staff turnover, it is crucial to be able to train employees quickly and deploy them flexibly. This also includes the location-independent use of mobile devices.

A modern WMS should not be rigidly programmed, but should consist of individual modules that can be combined as required.

Modules can be retrofitted if requirements change. The WMS therefore grows with you. The next mentions illustrate the desire for an integrated system. Integration takes place both upwards into the ERP system and downwards into the material flow control system, including connection of the control technology and visualization of the entire material flow. In terms of hardware, the new system should also fit seamlessly into the IT landscape.

Processes can be optimized and throughput increased by systematically collecting and evaluating data from the operation of the logistics center.

Fig. 7: Required functions of a new avalanche transceiver. © Unitechnik
Fig. 7: Required functions of a new avalanche transceiver. © Unitechnik

What the provider should bring to the table

1. the provider of a warehouse management system must ensure that its software is always state of the art and is developed further in the long term. Continuous updating by in-house specialists ensures future-proofing, compatibility and stability. Equally important is reliable support that ensures smooth operation of the warehouse management system and intervenes quickly in the event of problems.

2 In addition, the provider should have comprehensive process knowledge and planning experience in intralogistics. This is the only way to analyze and optimize the existing material flow and warehouse processes together with the customer and adapt the WMS precisely to the individual requirements. The integration of adjacent systems such as ERP, MES or conveyor technology also plays a key role in enabling end-to-end digitalization of the logistics chain.

3. another decisive success factor is the provider's experience with WMS conversions during ongoing operations. Qualified project managers as permanent contacts ensure structured, transparent and timely implementation. A key component of this is the use of a digital twin of the system. With this virtual test environment, software, interfaces and automation systems can be tested prior to live operation.

Fig. 8: Desired services of an avalanche transceiver provider. © Unitechnik
Fig. 8: Desired services of an avalanche transceiver provider. © Unitechnik

Best practice - Successful avalanche transceiver replacement explained step by step

Step 1: Inventory of existing warehouse management and processes

For Unitechnik, the basis of every avalanche transceiver replacement is a thorough inventory of the existing avalanche transceiver system:

  • Processes
  • data structures
  • operator guidance
  • terminal devices
  • Interfaces to other IT systems
  • Subordinate control systems (conveyor technology, machines, etc.)
  • IT infrastructure

Step 2: Target definition and planning of the WMS modernization

The system operator and the provider of the new warehouse management system jointly define the functional scope of the new system.
Important questions here are:

  • Should the introduction of a new WMS be used to optimize processes, or should it be a copy of the old system?
  • How can modern end devices be used to make work more intuitive for employees?
  • Should neighboring systems also be updated or should the interfaces remain unchanged?
  • What special features need to be considered when migrating from the old to the new system?

Step 3: The digital twin - the key to a successful avalanche transceiver change

The digital twin plays a central role in automated logistics systems when introducing new warehouse management systems (WMS). It provides a virtual representation of the real warehouse with conveyor technology, robots and workstations and makes it possible to test functions and interfaces in advance.

This means that the old WMS can be replaced by the new system over a weekend - without interrupting operations. Stock levels and orders are simulated, processes are checked in real time or time-lapse and repeated as often as required until the replacement runs without errors.

An ultimate test run then looks like this, for example:
The current stock level is exported from the existing legacy WMS system and imported into the new system. At the same time, the orders for an entire day are imported from the higher-level ERP system. The new WMS processes the orders in conjunction with the digital twin - at the original speed or in fast motion. Everything can be observed via the visualization. In contrast to real operation, the day can be repeated as often as required.

Step 4: Staff training for safe handling of the new avalanche transceiver

Involving employees at an early stage is one of the most important success factors. This starts with the definition of work processes and continues when dealing with the new system. The digital twin also provides good support here. End devices and operating dialogs can also be tested before the real start - just as a pilot first trains in a flight simulator. Maintenance personnel should also familiarize themselves with system visualization and assistance functions at an early stage.

Step 5: Structured changeover and project management for the replacement of the WMS

Good project management is the basis for the success of a project - especially when replacing a warehouse management system. It is of paramount importance during the actual system changeover in intralogistics. Each work step must be clearly described, especially the responsibilities and the time schedule. In this way, the migration of the WMS runs in a structured, efficient and hectic-free manner and ensures a smooth transition during ongoing logistics operations.

Step 6: Support during ramp-up and stabilization of the new WMS

Despite the best preparations, minor problems can occur at one point or another during the system's start-up. It is now crucial that the experts who have programmed, tested and implemented the new warehouse management system actively support the operator. Following the principle of "helping people to help themselves", they accompany the logistics staff and maintenance staff during the start-up phase. This ensures that the WMS functions optimally, the intralogistics processes run stably and the system works reliably in the long term.

Practical example - Successful LVS replacement at Georg Fischer

Task
Turning three into one: this was the task that the Swiss industrial company Georg Fischer (GF) set Unitechnik. At the GF Piping Systems division sites in Schaffhausen, a future-proof all-in-one solution was to replace three different previous warehouse management systems and equip 110 WMS workstations. The challenge: The new UniWare warehouse management system had to replace a highly optimized system and map very complex logistics processes. It was equally important to the client that the changeover was possible without system downtime.

Solution
The case study "UniWare warehouse management system for central distribution center and external warehouses" at:
https://www.unitechnik.com/case-studies/georg-fischer.html reveals how Unitechnik implemented these requirements in detail.

The UniWare WMS is connected to the automatic pallet warehouse in the distribution center. © Georg Fischer
The UniWare WMS is connected to the automatic pallet warehouse in the distribution center. in the distribution center. © Georg Fischer

Conclusion - A successful avalanche transceiver replacement as the key to the digital future

The aim of the WMS replacement: to fully map the customer's material flow. © Unitechnik
The aim of the WMS replacement: to fully map the customer's material flow. © Unitechnik

One thing is certain: The replacement of warehouse management systems is complex - especially because it takes place during ongoing operations. The path to a customized WMS must therefore always be tailored to the individual case. It is advisable to select a provider that offers a standardized WMS with flexible customization options - such as UniWare from Unitechnik - to meet specific customer requirements. Emulation should be a fixed component in order to minimize the risk of conversion through pre-testing. This digital twin also helps to identify optimization potential with regard to logistical processes. After all, replacing a WMS is also an opportunity. Not only, for example, to integrate several isolated solutions into an all-in-one system or to map new business requirements once. In the best case scenario, the new WMS is able to react flexibly to process changes and retrofit new functions. This means that the company is fit for the future.

Your contact person

Ein freundlich lächelnder Mann mittleren Alters mit kurz geschnittenem, dunkelbraunem Haar trägt ein dunkelblaues Sakko über weißem Hemd und steht vor einem hellen, unscharf dargestellten Hintergrund.

Matthias Spies

IT-Consulting and Sales UniWare

T +49 2261 987-358
E-Mail | LinkedIn | vCard

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About Unitechnik - Your partner for automation, intralogistics and WMS systems

Unitechnik Systems GmbH, based in Wiehl, has been one of the leading providers of industrial automation, intralogistics and IT for five decades. Now in its second generation, the family-owned company plans and implements customized systems for in-house logistics, warehouse management and production. Innovative software concepts form the central building block for efficient material flows and digital process control. Unitechnik operates worldwide as a system integrator and complete supplier and offers comprehensive solutions for warehouse management systems, conveyor technology and production logistics. For many years, logistics consulting has complemented the portfolio as an independent service - customers benefit from decades of practical experience and technological expertise. References include well-known companies such as AS-Création, CLAAS, DEHN, Hela, Linde Gas, Nobilia, Soennecken, Testo and Turck.

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