Incorporating Wi-Fi in modern warehouse operations is essential in today’s fast-paced distribution environments. Speed and accuracy of employees, inventory management, and data are the key to efficiency and quality control. Using contemporary software to manage your operations, such as a warehouse management system (WMS) is essential. Equipping your workers with mobile devices and giving them continuous access to the software takes your efficiency to another level. But without reliable Wi-Fi connectivity, the results can be less than desirable, if not frustrating. Expensive software, mobile devices like barcode scanners, and people can be seriously hampered if they can’t all work together seamlessly and without latency. Implementing Wi-Fi in the warehouse plays a crucial role in maintaining an organized and responsive inventory system.
Have a Plan for Wi-Fi Implementation
The best way to ensure reliable Wi-Fi is to consider hiring a professional to perform a “site survey” to determine the ideal placement of Wi-Fi access points. The advantage is that they will have all the tools they need to make you have the right quantity of APs and their placement is optimal. Ideally, the survey should be carried out after the warehouse has been fitted out…. racks and equipment in place and inventory on the shelves. An empty warehouse doesn’t reflect real-world conditions, and the contents of a warehouse can dramatically affect Wi-Fi performance. It would be better to wait until the warehouse is near operational before optimizing the placement of access points. The investment in a site survey will pale in comparison to what you might spend chasing problems down the road.
Using Multiple Wi-Fi Networks
Virtually all network infrastructure equipment is controller-based, whether that be an on-premise controller or one that is cloud-based. These allow the Wi-Fi network to be managed and configured from one central interface. There can be numerous wireless networks bound to some or all of the various access points mounted throughout a facility. A common example would be to have an Office Wi-Fi network, a Whse Wi-Fi network, and perhaps a Guest Wi-Fi network. Each of these can be bound to specific access points located in certain areas and have its own level of security and band selection.
Access Point Placement
Try to follow the results of the site survey as closely as possible. If you opt out of the professional site survey, then at least distribute the access points in a logical manner. It may seem that simply installing them equidistantly throughout would be a good plan. But if two-thirds of the warehouse is filled with tall racking and inventory and the other third is packing stations, staging areas, and other ground level or low-profile fixtures, you’ll likely find you need more access points over the racking area than you do in the work areas.
Generally speaking, when it comes to the physical placement, installing them higher is better when placing access points. The exceptions would be (a) if the higher placement would put the access point behind an obstruction that might affect performance, or (b) the access point would end up 30 feet or more above the effective work area. However, attaching them to the ceiling is generally better than attaching them to a wall, as the wall will affect the propagation of the radio and might result in a weak signal. Ensure the selected location is free from the possibility of moisture ingress and minimal dust collection. If the mounting points of the ceiling are metal I-beams, consider suspending them from the I-beam by mounting them to an electrical gang box secured perpendicular to the end of a metal conduit that itself is mounted to the I-Beam.
Finally, you should have enough access points to give you some reasonable overlapping coverage to ensure seamless roaming and eliminating dropped connections. Most roaming problems and dropped connections occur because of an “overly optimistic” perception of how well the access points were deployed. At the outset, it may make sense to save money by buying fewer access points and spacing them conservatively, but the frustration of poor Wi-Fi performance is far more costly than a few more access points deployed more liberally. Conversely, too many access points can cause interference problems. Once again, the need for a professional site survey is highlighted.
Antennas
Signal coverage can be tricky. Many obstacles such as walls, tall racks, and the materials on those racks can interfere with the Wi-Fi signal. Antennas attached to the access points can either be directional or omnidirectional. The inclination might be to use omni-directional antennas everywhere but consider selecting the appropriate antenna based on the location of each access point. For example, it may be more effective to place an access point over the center of an aisle and use a directional antenna to focus the energy up and down the aisle. Note that some materials, like rolls of carpet, or stacks of cardboard, can present challenges to proper Wi-Fi signal propagation. Focus the energy on the aisles that workers will traverse, not on dense materials that will absorb radio waves.
Wi-Fi Band Selection
Typically, Wi-Fi networks will default to supporting both the 5Ghz and the 2.4Ghz bands when creating wireless networks on them. This is often well suited for office environments where the wireless client devices are, for the most part stationary. The Wi-Fi network that the mobile devices connect to, however, should be configured for only one of those bands. Otherwise, disconnects can occur when the handheld device switches from one band to another. The 5Ghz band would be the preferred band to use as it supports faster speeds, but the 2.4Ghz band will allow for more range, at the cost of a slower connection. Given sufficient access point coverage, the 5Ghz band, or 6Ghz when supported, should offer the needed Wi-Fi coverage area.
Channel Planning
Wi-Fi networks have specific “channels” they operate on, just like a freeway has several lanes of traffic. If everyone drives in the same lane, traffic congestion occurs and everyone slows down. Distribute the load on your access points across multiple channels to avoid interference. Controller-based Wi-Fi networks 
perform a functionality of what is called DCA (Dynamic Channel Assignment) that will handle setting each access point’s channel, however, this does not always assign the proper channels when the 2.4Ghz band is being used. These often need to have their channels assigned manually so that access points that are next to each other are each set on a non-adjacent channel of 1, 6, or 11.
In the diagram, the squares represent physical access points, while the circles represent their radio propagation area. Note the overlap. The numbers on the access point represent the channel numbers the particular device should be set to minimize congestion and maximize bandwidth. Note that no two adjacent access points are set to the same channel.
Power
Signal strength can be controlled on the access points by adjusting their transmit power. It may make sense to simply set the power to maximum, but not so. Increasing the power may accentuate interference problems and cause mobile devices to connect to access points further away. Take a balanced approach to power settings. Increase the power when necessary, on a specific A/P, but otherwise try to keep the power settings balanced.
Network Security
Network security is vital in a warehouse environment due to the large number of devices and sensitive data involved. Unauthorized access can lead to data breaches and operational disruptions. Implement strong authentication protocols such as WPA3 to secure connections and protect confidential information. VLANs can be used to isolate the wireless network from other networks containing sensitive information. Not allowing the Wi-Fi network to broadcast its name (SSID) is generally not a good idea. It does nothing to improve security while creating an inconvenience for the users.
Monitoring network activity is essential for spotting unusual behavior that might indicate a security threat. Use firewalls and intrusion detection systems to safeguard the network against attacks and then regularly perform security audits.
Summary
In summary, quality Wi-Fi in the warehouse is necessary for maximum productivity, so start with a plan and, if possible, hire a professional to conduct a site survey after the warehouse is fully equipped. Reliability is the key. Despite the additional costs, one or two additional access points are better than 1 or 2 less, to give you some overlapping coverage. Higher is better than lower when it comes to mounting and installation. If you are uncertain about the proper settings on the access points, like channel selection and power, hire a professional to handle these for you. Spending a little time and money upfront is a lot easier than chasing Wi-Fi connectivity problems at the most inopportune time. And don’t forget security settings and firewalls to protect not only your Wi-Fi network but your business as a whole. When implementing Wi-Fi in the warehouse, there may be some obstacles and challenges to overcome. AML’s highly experienced support team is just a phone call away.
