Projection System Laser Technology for Increasing Efficiency in Logistics

Making logistics processes safer, more efficient, and faster is the task of LARS. The laser-based projection system developed by Fraunhofer researchers guides employees in real time through warehouses via a light trail, providing orientation—especially for new and unskilled workers.

Companies are facing an increasing shortage of skilled workers—in industries such as logistics, the lack of labor is significant, often requiring the use of career changers and unskilled workers. Additionally, there is high turnover and the need to hire extra temporary staff during peak seasons. However, integrating new, inexperienced employees into complex processes is often time-consuming.

Guide Playfully through the Warehouse

This is where LARS, short for Laser-AR-Safe, comes in: researchers at the Fraunhofer Institute for Material Flow and Logistics IML have developed the laser-based projection system to assist employees in intralogistics halls with their daily tasks. With the ability to dynamically and flexibly display individual information such as routes, storage locations, signs, and order numbers, LARS guides users playfully through the warehouse and precisely through work processes. The necessary knowledge can be conveyed during initial training or when processes change simply through the projections. The need to search for goods or figure out where to place something is eliminated. The laser projection displays the required information.

"In many warehouses today, there are people who do not speak German well or are barely trained. Our system uses symbols, numbers, and colors, making the tasks more comprehensible," says Rico Ahlbäumer, a researcher at the Fraunhofer IML. "Instead of long texts or cryptic picking slips, there is a clear, instantly understandable indication on the floor." For example, a blue arrow shows the way to the correct ramp, and a green square indicates where a pallet should be placed. "The transmission of information via light could potentially replace floor markings in warehouses in the future," says the researcher.

Combination of Hardware and Software

The modular, scalable guidance system combines hardware and software: the laser projectors are mounted on the ceiling, although they can also be attached to high racks if desired. A maximum of 200 projectors per hall is possible. However, five lasers are sufficient to display instructions across an area approximately 30 meters wide in up to twelve lanes. The projection area depends on the height of the hall. The projected light is safe for the eyes thanks to an integrated expansion lens, and the brightness and scattering of the laser light can be adjusted. The selection of displayable colors and shapes is entirely flexible. One software controls the projectors, while another software developed by Ahlbäumer and his team enables the projection of images onto the floor. LARS can be connected to various logistics systems upon request and is typically supervised by the warehouse manager.

With LARS, the researchers are pursuing a human-centered approach to specific problems, tailored to the needs of employees. The use cases range from picking and consolidating to palletizing or sorting. LARS is also conceivable as a navigation system for the shop floor.

Practical test successfully completed

With a successful practical test at Rhenus Logistics, researchers at the Fraunhofer IML were able to demonstrate the effectiveness and operational efficiency of LARS. With the ability to support multiple employees simultaneously, LARS is an ergonomic and scalable solution for modern work environments. "The complexity in intralogistics is continuously increasing due to factors such as shorter delivery times, smaller batch sizes, growing product diversity, and the shortage of skilled workers. With LARS, companies in logistics and production gain a flexible tool to address these challenges," says Ahlbäumer.