Integrating Your Conveyor System
If you’ve ever worked in a warehouse where systems don’t talk to each other, you know how frustrating things can get. Orders go missing, boxes end up at the wrong dock, and employees waste time chasing down inventory instead of moving it forward. Mistakes pile up, productivity stalls, and your bottom line takes a hit.
Whether it’s a small-scale venture or a massive production line, the difference between a reactive facility and a high-performing one almost always comes down to integration of your warehouse management system (WMS).
In this blog, we’ll walk through what that integration looks like, how it works, what you gain from it, and the common mistakes that can derail a project before it even starts.
What is Conveyor System WMS Integration?
So, what does WMS-conveyor integration really mean? Let’s break it down with a simple analogy. Think of your WMS as the warehouse’s brain. It keeps track of inventory, manages orders, and decides what needs to go where.
Your conveyor system is more like the muscle. It moves the product from one point to another, whether that’s picking, packing, shipping, or storage.
Integration is what lets the brain, and the muscle speak the same language. When the WMS gives an instruction, the conveyor doesn’t wait around. It just does it. No printing a slip, no hand-delivering the order, no delays. It all happens automatically.
Why Integration is a Game-Changer
When your systems are connected properly, you’ll see quite a bit of difference. Some of the biggest benefits include:
- More orders completed per hour
You can push more volume without adding headcount.
- Fewer mistakes
Orders don’t end up in the wrong truck because nobody typed the wrong lane number.
- Real-time tracking
You’re no longer guessing if something has shipped. it’s right there on the screen.
- Lower staffing needs
With fewer manual touchpoints, your team can handle more work.
- Better growth potential
When demand spikes, your system won’t fold under pressure.
How It Works: A Look Under the Hood
How does WMS and WCS break down? What is the hierarchy of these systems? Below, we’ll explore the flow:
- WMS
At the top of the stack is the WMS. The WMS knows what orders are pending, where inventory is stored, and what needs to ship. It decides what to move and why.
- WCS
The Warehouse Control System (WCS) sits in the middle. It takes the WMS’s instructions and breaks them down into steps the machines understand. So, the WCS figures out which conveyor needs to start, where to send the product, and when to trigger the next move.
- PLCs
At the bottom of the system are Programmable Logic Controllers (PLCs). PLC conveyor control systems are industrial computers that physically operate the conveyor, turning motors on, flipping diverters, reading barcodes, and scanning sensors.
Most modern setups use REST application programming (APIs) to make all this communication happen quickly and securely. Older systems might still rely on CSV files or EDI, but those are slowly fading out as real-time visibility becomes non-negotiable.
The Biggest Challenges with Warehouse Management System Integration
Even the best setup can run into problems if it’s not planned right. Some of the most common issues of WMS integration include:
- Bad communication between systems
If your WMS and WCS don’t understand each other, everything falls apart.
- Old hardware that doesn’t play nice
Some conveyor systems weren’t built for modern integration and might need upgrading.
- No plan for “what if” moments
Packages will jam. Scanners will miss. Your system needs backup instructions for when things go sideways.
- Skipping the testing phase
Find bugs before your first live order rolls through the line.
The Big Picture
Connecting your WMS with your conveyor system is a major shift in how your warehouse runs. It means fewer fires to put out, more control, and a system that grows with your business.
Whether you’re running a small operation or overseeing a high-volume distribution center, integration isn’t just smart, it’s an essential part of growing your business.
Russell Conveyor and Equipment is proud to be a leading provider of conveyors and warehouse automation solutions. Our experts have years of experience designing custom conveyor systems, and we can help you get yours up and running smoothly. Call us at (336) 526-3014 for more information and let us create a conveyor that moves your products at the speed you need your business to go.
FAQs About Warehouse Management System Integration
It makes sense that you would have a few questions about integrating your conveyor system with WMS technology. To help illustrate this process, we’ve answered some common questions on the subject:
Production lines that aren’t adequately connected to warehouse management systems suffer from longer delays, increased manual labor, and more mistakes.
Sometimes yes, sometimes no. Some setups can be brought up to speed with new controls, but in other cases, it might be smarter (and cheaper long-term) to replace parts instead of trying to force them to work
They sound similar, but they handle different sides of the operation. The WMS tracks inventory and orders. The WCS talks directly to the machines and makes things move. One’s planning, the other’s doing.
Both. When the system takes care of routine stuff, like routing boxes or reading barcodes, your team can focus on work that needs a human touch.
Every job is different, but most take a few weeks to a few months depending on how complex the system is.
APIs are what most people use now. However, some operations still run on older setups like flat-file transfers. It really comes down to what your current systems can handle.