Oct 03, 2023

Here are two words that spark both excitement and dread in the distribution center: Warehouse Robotics. For the past decade, warehouse automation has been widely sought after but also misunderstood. Decision-makers tend to see robotics as a sure way to decrease labor costs and expedite workflows without compromising accuracy rates. On the other hand, indispensable warehouse workers may see robotics as a threat set to replace them. Surveys conducted by the Pew Research Center found that 42% of workers feel robots will displace jobs. The rise of artificial intelligence has now also contributed to these fears, as automated mobile robots (AMRs) can now be programmed to chart paths and complete workflows based on collected data and preset algorithms. Modern robotic systems are currently supporting the following workflows:

• Automated SKU Sorting

Incorrect sorting at the receiving dock sets up the supply chain for costly disruptions, such as product shrinkage and overstocking. Automated scanning has helped speed up sorting by removing manual touchpoints, but warehouses handling large influxes of inventory -as most do during peak seasons-may need more assistance. Sorting robotics equipped with machine vision and conveyors can help direct incoming inventory to the correct aisle while freeing up teams to accomplish more complex tasks.

• Order Picking

Order fulfillment can account for over half of total operational costs when you factor in labor and storage. Varying similar-looking SKUs can increase costs since they are most likely to be confused and mis-picked. Consequently, fast-paced distribution centers are integrating picking robotics to locate and move the correct order to the loading dock, thus accelerating throughput rates.

• Pallet Transportation

Cross-docking workflows can be very labor-intensive, placing workers at risk of injury. For example, OHSA estimates over 30,000 forklift-related injuries happen per year, most involving pedestrians. Warehouse robotics can help protect workers by carrying large pallets following a preset route.

Leading automation experts foresee over 50,000 warehouses implementing AMRs and automated guided vehicles (AGV) by 2025. Therefore, to stay in step with consumer demands and competing markets, distribution centers must evaluate their current operations to see where next-generation automation fits to empower their current workforce. 

Your operations are ready for robotics if…

1. A flexible wireless infrastructure is set.
   While not every AMR needs to be connected to WiFi, a reliable network system is still vital to make sure robots receive signals as they travel throughout your facility. Dead zones and patchy networks will limit the travel routes your AMRs can take; therefore, consider assessing your network beforehand to ensure it can accommodate more devices without lagging systems. 
   
   
2. Bottlenecks are identified.
   The primary objective of implementing automation solutions within a workforce is to alleviate any constraints or limitations currently experienced by employees. To effectively introduce robotics as a solution to persistent issues, it is crucial to first identify any bottlenecks that exist within the current system. By doing so, workers can better understand how robotics can be used to enhance their existing efforts, rather than being viewed as a replacement for their labor. One example of this is the complex put-away process, which can be effectively systemized using robotics. This solution empowers workers by providing them with greater control over where inventory is stored and ensuring that incoming pallets are accurately processed at the point of receiving. By leveraging the power of automation in this way, organizations can optimize their processes while also providing a safer and more efficient work environment for their employees. 
   
   
3. The workforce is already using automated data capture.
   Surprisingly, there is still a vast majority of warehouses and distribution centers relying on manual recording to track and assemble orders. Automated data capture systems interfacing with your WMS can be paired with AMRs, closing the learning gap as workers don’t need to worry about learning two new systems. 
   
   
4. Your WMS is already digitized.
   Furthermore, real-time WMS updates via an automated scanning system provide greater inventory control as teams can pinpoint stock location at any given time. Equipped with this knowledge, AMRs may be programmed to follow the most efficient pick paths based on accurate data. Apart from robotics, a digitized WMS is also extremely beneficial to facilitate audits and traceability in other supporting workflows. 
   
   
   
   
5. A security plan is in place.
   To prevent accidents and collisions, warehouse robotics may be equipped with intelligent scanners and infrared sensors. However, a preliminary conversation with your team covering best practices and expectations can help prevent future accidents stemming from asset misuse. Advanced systems may even include smart cameras to scan human movement and pause routes until pathways are cleared.
   
   
6. You have an asset management plan.
   As with any other automated system in your facility, warehouse robotics will require consistent support and maintenance to update software, track route changes, and configure automated queues. Proactive asset management will not only help smooth rollouts and device configuration, but it will also keep your systems updated, notify you of upcoming servicing, and provide remote troubleshooting to secure unbroken uptime. 
   
   
7. You’ve identified the inventory to be transported.
   Last but certainly not least, automation specialists recommend assessing your inventory type and piloting your AMR solution with a specific kind of stock to adjust your solution without halting overall productivity. Consider documenting information such as inventory weight, dimensions, packaging, and storage requirements to match your inventory to the correct automated robot.
   

How to evaluate your operations for robotic implementation

In today’s high-demand climate, automation is not an option but an expectation. By scheduling a comprehensive workflow evaluation, businesses can gain a better footing in starting their solution, ensuring their teams are empowered with the technologies and support they need to best accommodate robotic systems. While distribution centers may have different reasons fueling the need for modernization, it is generally accepted that a robotic system will help enable:

• Higher throughput rates without overwhelming workers
• Accurate data for demand forecasting
• Faster training cycles for seasonal workers who won’t need to worry about learning repetitive tasks
• Increased worker satisfaction
• Greater inventory control that comes from a unified tracking system

As supply chains continue to navigate through new demands and legacy challenges, automation experts only expect to see robotics play a greater role in the modern warehouse. Despite their intelligence, many specialists admit they will not replace the human workforce, but rather create new opportunities and roles within the supply chain. To learn more about warehouse robotics with our in-house specialists, set up a preliminary meeting with our experts.