WHAT IS WAREHOUSE ROBOTICS? A GUIDE

In the ever-changing logistics landscape, automation has brought about a new era of efficiency and productivity in warehouse operations. In this blog post, we will discuss the concept of warehouse robotics, the most common types of automated warehouse robots, the benefits they offer, and important considerations before investing in such a solution. 

What is robotics in warehousing? 

Warehouse robotics refers to using automated robots and robotic systems to perform various tasks within a warehouse or distribution center. These robots are designed to enhance the efficiency, accuracy, and productivity of warehouse operations by automating repetitive, time-consuming, or physically demanding tasks traditionally performed by human workers.  

How robots are used in warehouses? 

Robots in warehouses can be used for a wide range of processes. They can be programmed to navigate through warehouse aisles, pick and place items, transport goods, or perform sorting and packing operations. Some of the key warehouse processes where robots are commonly deployed include:   

- Order picking:

- Packing and packaging:

- Palletizing & depalletizing:

- Material handling:

- Inventory management

- Sorting:

- Quality control:

- Receiving and unloading:

Robots can unload items from trucks or containers and place them in designated storage locations. 

Why is warehouse robotics so popular?  

The increasing popularity of warehouse robotics stems from the following challenges:  

• E-commerce growth: the rise of e-commerce has led to a significant increase in order volumes and fulfillment demands.  
• Faster order fulfillment needs: Customers today expect quicker order processing and delivery times. 
• Labor shortages: There is a shortage of available labor across the warehousing industry. 

Robotics in warehousing can address these challenges. It enables businesses to stay competitive in a fast-paced market, meet growing customer demands, and adapt to changing industry trends. 

What different types of warehouse robotics are there? 

There are various solutions to meet different operational needs. Each brings its own benefits and capabilities to the warehouse environment. Here is a list of the most common ones:  

1. Automated Guided Vehicles (AGVs):

AGVs are used in warehouses to automate the movement of goods and materials within the facility. They typically rely on fixed physical guidance systems, such as magnetic tape or guide wires embedded in the floor, to follow predetermined paths or routes within the warehouse. They are well-suited for repetitive tasks and fixed routes. Once their paths are set, they follow them consistently.

2. Autonomous Mobile Robots (AMRs):

AMRs are similar to AGVs but use more advanced navigation technologies, such as LiDAR (Light Detection and Ranging), cameras, and sophisticated algorithms to sense and map their surroundings. They can navigate through dynamic environments and adapt to changing conditions, making them more flexible and suitable for warehouses with varying layouts. 

3. Automated Storage and Retrieval Systems (AS/RS):

AS/RS robots are computer-controlled robotic systems to automate the storage and retrieval of items. They are designed to efficiently manage inventory, optimize space utilization, and streamline warehouse operations. The robots use cranes, shuttles, or other automated mechanisms to store items in designated storage locations and retrieve them for further order processing, like order picking and packing. By replacing conveyors during the movement of totes/pallets to and from the storage area to the pick station, they facilitate a versatile solution. 

Autostore robots are a particular type of AS/RS solution. They are a cube-based storage system operating within a grid-style structure consisting of stackable bins or containers. The robots move on the grid and access the bins from above, enabling efficient storage and retrieval of items. Autostore robots offer high-density storage capabilities, as well as the ability to handle a large number of SKUs simultaneously. 

4. Palletizer robots:

Palletizer robots automate the process of placing boxes or items onto pallets, following predefined patterns or configurations. They can handle various box sizes, weights, and shapes, making them versatile for different types of products. They can work at high speeds, significantly increasing the throughput and efficiency of the palletizing process while reducing worker strain from manual lifting and palletizing. 

5. Robotic Arms:

Robotic arms are equipped with multiple degrees of freedom, allowing them to mimic human arm movements and perform a wide range of precise and complex operations. Some common uses of robotic arms in warehousing include picking, packing, sorting, and palletizing.  

6. Drones:

Warehouse drones (or UAVs – Unmanned Aerial Vehicles) are equipped with multiple sensors, cameras, and navigation systems that allow them to fly and navigate through warehouses. They can perform a range of tasks, such as scanning inventory, performing security surveillance, inspecting hard-to-reach areas, and monitoring environmental conditions. Some warehouses also use drones to transport small, lightweight items inside the facility.

7. Collaborative Robots (Cobots):

Cobots can possess a certain level of autonomy. However, their design and programming prioritize safe and interactive collaboration with human workers, distinguishing them from fully autonomous robots operating independently in more controlled environments. They are used to enhance productivity, improve efficiency, and augment human capabilities in various tasks, e.g., picking or lifting heavy items. 

What are the benefits of warehouse robotics? 

The modern logistics organization operates on fine margins and relies on optimization, efficiency, and exceptional service to stand out from the competition. Using robotics in warehousing can have a significant positive impact on all these factors and many more. Key benefits include: 

Increased efficiency: Warehouse robotics can perform tasks faster and more accurately than human workers. They can work continuously without breaks, leading to higher throughput and reduced processing time for various operations like order picking, packing, and palletizing.
Improved accuracy: Robots are precise and consistent in their actions, reducing errors and minimizing product damage. This accuracy results in improved order accuracy, inventory management, and lowered costs associated with mistakes. Enhanced safety: Robots can take over hazardous, repetitive, or physically demanding tasks from humans. This shift in workload reduces the risk of injuries, elevates overall worker well-being, and fosters a safer work environment.
Optimal space utilization: Warehouse robotics, such as Automated Storage and Retrieval Systems (AS/RS), maximize vertical storage space by utilizing high-bay racking structures. This optimized space utilization allows warehouses to store more products in a smaller footprint, increasing storage capacity without expanding. Labor savings: By automating repetitive and physically demanding tasks, warehouse robots reduce the need for manual labor. This leads to cost savings in workforce expenses and allows human workers to focus on more strategic and value-added tasks. 

What should I consider before investing in warehouse robotics? 

With numerous solutions available in the market, the question arises: which one to implement? There are several important factors to take into account for successful implementation. Here are some key considerations:

Warehouse layout and design:

Analyze your warehouse layout and design to determine how robotics can be integrated effectively. Consider the available space, storage systems, and potential bottlenecks. 

Operational requirements:

Assess your specific operational needs and challenges. Identify areas where automated warehouse robots can provide the most significant improvements. 

Cost-benefit analysis & ROI calculation:

Conduct a thorough cost-benefit analysis to understand the financial implications of your planned investment. Determine the expected return on investment (ROI) and payback period. Make sure it aligns with your business goals and financial objectives. 

Scalability and flexibility:

Evaluate the scalability and flexibility of the solution. Will it be able to adapt to future changes in your warehouse operations and accommodate growth? Consider potential advancements in warehouse robotics technology and assess how your chosen solution may evolve in the future.

Vendor reputation, customer support, and maintenance:

Research the solution's reliability and maintenance requirements. Choose a reputable and reliable vendor with a track record of successful robotics implementations. 

Training and workforce:

Consider the impact of warehouse robotics on your current workforce. Determine if additional training will be required for employees to work effectively alongside the robots. 

Integration with existing systems:

Conduct research on how the automation solution will integrate into your current warehouse ecosystem. How can you ensure seamless integration? Let's discuss it in further detail. 

Warehouse robotics integration – how to do it right? 

 Ensuring seamless coordination and communication between your automated warehouse robots and the existing warehouse ecosystem is critical. To make everything work together smoothly, you need to build up a well-connected solution considering two integration levels: 

• Integration with the warehouse management system (WMS):

Even highly automated warehouses use a combination of manual and automated processes. The WMS dictates the decision-making logic for both. It is like the “brain” of your warehouse, managing the What, When, and Where of it all. 

• Integration with the warehouse control system (WCS):

In the case of more complex goods handling flows, a WCS controls how your warehouse robotics perform tasks. It manages flow control and acts as a message broker between the robots and the WMS. With multiple automation solutions, this integration level is essential to avoid "Islands of Automation," where different automated robots in the warehouse work unsynchronized, leading to data discrepancies and sub-optimal performance. A good WCS has a plug-in architecture that can integrate with all kinds of automation suppliers, giving you the freedom of choice and flexibility in growing your business.  

To sum it up, think of your warehouse robotics as the muscles to do the job. The WCS controls how the job is done, while the WMS ensures you do the job right. 

Summary 

Automated robots in the warehouse replace the human workforce in various tasks by leveraging their speed, precision, and continuous operation capabilities. They are designed to work in repetitive and physically demanding environments, reducing the risk of injury and providing a safer working environment for humans. Additionally, robots can operate 24/7 without fatigue, leading to increased productivity and faster task completion. 

Implementing robotics in logistics can significantly improve operational efficiency, reduce errors, and optimize resource utilization, ultimately leading to cost savings and enhanced customer satisfaction. 

As technology advances and robotics become more accessible, the benefits of using warehouse robotics are expected to become even more pronounced, enabling warehouses to remain competitive and responsive to the demands of the modern supply chain. 

Looking to find out more?

Discover more in our webinar about 'AI & Robotics: Shaping the Future of Warehousing.' Gain insights into the future of warehousing with AI and robotics, find the right balance between robots and humans, and learn how to enhance warehouse profitability and sustainability with these technologies.